Assuring quality and meeting throughput targets whilst maximizing protection for man and machine

In the production of body parts, quality and throughput targets must be right. Therefore, SICK sensors are used in nearly all areas of the press room – with its many automated press lines and robot assembly areas. They ensure maximum readiness to deliver and direct the components and ready-to-fit systems to the production lines – at the correct point in time.
 

SICK combines precision, speed and safety

The construction of body in white is one of the vital production steps in automotive construction. This is where the various components are put together for a strong and homogeneous vehicle base. The foundation of the vehicle – the body – evolves.
SICK sensor solutions contribute to matching precision with speed and safety.

The right components and modules, at the right time, in the right place.

This is the basic principle of final assembly. It centres on logistics and quality. Only thus can the car, as a product, be produced perfectly and in accordance with the customer’s wishes. Whether identifying bodies, inserting screens, collision protection on suspended conveyors, supplying the wheels and many other applications: SICK sensors are everywhere, to ensure fluid processes.

SICK sensor solutions ensure precision and safety.

To ensure that engine components form a perfect whole, SICK sensors perform vital monitoring, control and safety tasks in all areas of the “power train”. For example, in checking for the presence of workpieces, control of gantry robots, lubricants control in the engine or control of the workpiece carriers on transfer lines – and, last but not least, in protecting hazardous points and areas.

Prior to delivery the adjustments on the seats are checked. An IQ80 inductive proximity sensor signals the presence of a carrier and stops the transport. Two DME5000 distance sensors measure the seat adjustments to be checked. For this purpose the worker pushes the seat to its front and rear position and reads the two measured values directly on the display on the bottom DME5000.

The ICR840 code reader reads the two-dimensional code applied by a laser (direct part marking) to a camshaft and checks whether the correct camshaft is fitted. The device sends the information to a central computer for quality assurance.

Tire identification using the OPS890 bar code reading system. The system comprises eight CLV490 line scanners arranged to reliably detect the bar code on the tire bead. The reading system is triggered by two WL18 (A) photoelectric reflex sensors that are arranged in an X-shape in the reading zone to reliably detect the tire. Two further WL18 (B) photoelectric reflex sensors arranged one over the other provide fast pre-adjustment of the position of the focus of the code reader.
The large depth of field of the devices does not require any further adjustment.

A handling robot fits two sealing rings to injection nozzles. It picks up the injection nozzle from the conveyor belt and places it in the receptacle on the assembly table (process not shown here). A WT12L laser photoelectric proximity sensor monitors for presence in the receptacle and the exact positioning of the nozzles. The rings are supplied on two vibration conveyors. WF fork sensors mounted at the outlet on the conveyors control the vibration conveyors such that rings are always available. IQ05 inductive proximity sensors check the presence of rings in the two pick-up stations. The handling robot collects a ring using end effectors attached to its pivoting arm and fits it to the nozzle.

Semiconductor front-end
Clean-room conditions, aggressive media, high temperatures, poorly accessible sensor locations – wafer processing and quality assurance make extreme demands on detection and safety technology. These sensor systems from SICK are ready for them: compact, robust, easily installed, reliable and powerful.

Semiconductor back-end
Those who produce chips cannot afford to make any compromises. Too much depends upon the quality of the components. Production process requirements are correspondingly high. From detecting the presence of “naked” lead frames in a stack, to inspecting the quality of finished encapsulated and separated chips – SICK sensors permit assured production with high cycle speeds.

The production of electronic circuit boards is subject to particular price pressure, whereby the quality must be right. High-end results in maximum possible cycle speeds – SICK sensors and camera systems permit increases in performance at all points of PCB assembly, from the first loader contact to feeding of the assembled circuit boards to the soldering oven.

Electronic products
Controlling conveyor belts, checking occupancy, identifying workpieces – the final assembly of electronic products demands versatile, flexible and economical sensor solutions. SICK offers precisely the product portfolio required: distance sensors, vision cameras, photoelectric sensors, proximity sensors, bar code readers and safety systems – technically sophisticated and proven in the most varied of applications.

The future-oriented solar sector: the more efficient the production of cells, the more reasonably priced this environmental technology – and the quicker it will assert itself.
SICK makes a decisive contribution towards accelerating processes. Protecting hazardous points-of operation, checking presence, production steps in wet areas, contour measurement and quality inspection: SICK sensors support your automated solar cell production.

During the assembly of solar modules, solar cells are combined, framed and encapsulated for weatherproofing to form larger units – the modules. SICK sensors have a key position in each individual step of the process – from the stringer, through foil attachment and lamination, to quality assurance and handling of the end product, the solar module.

Identifying transparent objects (e.g. PET bottles), coping with contamination, detecting positions in the process, and all of this at high speeds – the robust sensors from SICK have been “at home” in rotative filling systems for decades and offer correspondingly optimized performance.

Composite cartons have proved ideal (because hygienic), nutrition-retaining, economical and logistically advantageous primary packaging of drinks, dairy products and other liquid foods. The steps from the box to correctly filled packaging are many and varied. Leading in the process – from start to finish: efficient sensor solutions from SICK.

The hygienic demands of food legislation force the meat-processing industry to make special efforts during the construction and operation of their machines and plant. Temperature, humidity and the stipulated plant cleaning cycles with caustic solutions can drastically affect machine technology, and particularly the electronics. After many decades of proven performance and reliability under the harshest of conditions, inductive sensors, photoelectric switches and hand-held scanners from SICK have lived up to the challenge.

The sensors in bag packaging machines control the cutting of the bags, regulate their filling, and check the sell-by date. The solution for the entire process chain is illustrated here using the example of cereal packaging.

Inserting a variety of chocolates correctly and rapidly in the right mix is a task whose solution requires a highly complex robot system. Motor feedback systems from SICK are ideal “feelers” for all pick & place robots.

Attaching small, thin labels and reliably checking them, even if they are strongly reflective is critical for a labelling machine. Photoelectric sensors and photoelectric proximity sensors provide the necessary sensitivity to allow them to shine in labelling machines – reliably at maximum work speeds.

The cartoning of articles is a complex process, in which SICK sensors take on the most varied of tasks. IO Link, the innovative interface from SICK, ensures maximum process efficiency and rapid, comfortable conversion during format changes.

The pharmaceutical industry cannot afford any mistakes – neither in primary nor in secondary packaging of medicaments. SICK sensors recognize all poorly printed codes and reliably inform the machine controller.

Identifying transparent objects (e.g. PET bottles), coping with contamination, detecting positions in the process, and all of this at high speeds – the robust sensors from SICK have been “at home” in rotative filling systems for decades and offer correspondingly optimized performance.

Composite cartons have proved ideal (because hygienic), nutrition-retaining, economical and logistically advantageous primary packaging of drinks, dairy products and other liquid foods. The steps from the box to correctly filled packaging are many and varied.
Leading in the process – from start to finish: efficient sensor solutions from SICK.

Secondary packaging with shrink foil has become firmly established in the beverage industry. A proven ensemble of SICK sensors handles the fine work and final inspection.

Differing package shapes and sizes, the handling of packaging materials including protection of hazardous points-of-operation, ensuring material flow, differing reading distances for ID carriers: those who develop plants for industrial final packaging face a wide variety of tasks. Then there are the quality demands: the goods must arrive to customers in perfect condition. It is good to know that there is a partner that offers the sensors, safety and bar code reading systems from a single source: SICK, the solution for final packaging plants of all types.

The hygienic demands of food legislation force the meat-processing industry to make special efforts during the construction and operation of their machines and plant.
Temperature, humidity and the stipulated plant cleaning cycles with caustic solutions can drastically affect machine technology, and particularly the electronics. Many decades’ proven performance and reliability under the harshest of conditions: inductive sensors, photo electric sensors and hand-held scanners from SICK.

The sensors in bag packaging machines control the cutting of the bags, regulate their filling, and check the sell-by date.
The solution for the entire process chain is illustrated here using the example of cereal packaging.

Inserting a variety of chocolates correctly and rapidly in the right mix – a task whose solution requires a highly complex robot system.
Ideal “feelers” for all pick & place robots: motor feedback systems from SICK.

Attaching small, thin labels and reliably checking them, even if they are strongly reflective: photoelectric sensors and photoelectric proximity sensors provide the necessary sensitivity to allow them to shine in labelling machines – reliably at maximum work speeds.

Differing package shapes and sizes, the handling of packaging materials including protection of hazardous points-of-operation, ensuring material flow, differing reading distances for ID carriers: those who develop plants for industrial final packaging face a wide variety of tasks. Then there are the quality demands: the goods must arrive to customers in perfect condition. It is good to know that there is a partner that offers the sensors, safety and bar code reading systems from a single source: SICK, the solution for final packaging plants of all types.

Differing package shapes and sizes, the handling of packaging materials including protection of hazardous points-of-operation, ensuring material flow, differing reading distances for ID carriers: those who develop plants for industrial final packaging face a wide variety of tasks. Then there are the quality demands: the goods must arrive to customers in perfect condition. It is good to know that there is a partner that offers the sensors, safety and bar code reading systems from a single source: SICK, the solution for final packaging plants of all types.

Identifying transparent objects (e.g. PET bottles), coping with contamination, detecting positions in the process, and all of this at high speeds – the robust sensors from SICK have been “at home” in rotative filling systems for decades and offer correspondingly optimised performance.

Tubes are practical and particularly robust containers for semi-liquid goods. Tubes carry a wide variety of brand messages to consumers. The industrial filling and sealing processes involve a variety of tasks for sensors, e. g. turning tubes to the correct position. Sensors from SICK keep everything in view and under control.

Attaching small, thin labels and reliably checking them, even if they are strongly reflective: photoelectric switches and photoelectric proximity switches provide the necessary sensitivity to allow them to shine in labelling machines – reliably at maximum work speeds.

Differing package shapes and sizes, the handling of packaging materials including protection of hazardous points-of-operation, ensuring material flow, differing reading distances for ID carriers: those who develop plants for industrial final packaging face a wide variety of tasks. Then there are the quality demands: the goods must arrive to customers in perfect condition. It is good to know that there is a partner that offers the sensors, safety and bar code reading systems from a single source: SICK, the solution for final packaging plants of all types.

A sensitive topic – literally: the filling of syringes in the pharmaceutical sector.
Maximum hygienic and process reliability demands apply here. The technology of choice, when minimum tolerances matter to the filling process: high-performance sensors from SICK.

Sensors for linear bottle filling must be versatile.
Robust, powerful and meeting all demands:
sensors, safety switches and photoelectric sensors from SICK.

Tablets in blister packs, correctly printed with brand labels and use-by date, ready for comfortable individual removal – what seems so convincingly simple as an end-product makes complex demands on the packaging process in the pharmaceutical industry.
Accurate filling, precise sealing, detection of breaks, and freedom from dust are merely examples of the extensive performance profile. Your partner for the complete solution: sensor systems from SICK.

Attaching small, thin labels and reliably checking them, even if they are strongly reflective: photoelectric sensors and photoelectric proximity sensors provide the necessary sensitivity to allow them to shine in labelling machines – reliably at maximum work speeds.

• Commissioning with RFID and volume measurement
• Access protection
• Height measuring and position detection
• End position detection

• Log measurement
• 3D log measurement
• Height measuring and diameter detection
• Access protection

• Quality determination
• Volume determination
• Distance measurement
• Filling level measurement with radar
• Filling level measurement with rotating paddle switch

• Cant measurement
• Wane measurement
• Board detection
• Cant detection
• Position detection

• Lumber measurement
• Hazardous point-of-operation protection
• Filling level and board detection
• Board detection
• Path measurement
• End postition detection

• Log measurement
• Veneer measurement
• Distance measurement and end position detection
• Access protection
• Path measurement

• Cross cutting calculation
• Quality determination
• Access protection
• Package ejector

• Hazardous point-of-operation protection
• Board detection
• End of material detection
• Access protection
• Width measurement

• Pallet storage and retrieval
• Automated conveyor loading
• AGV contour navigation in shipping/receiving
• Extendable conveyor loaders
• Forklift automation and safety
• Depalletizer station

• DWS (Dimension, Weighing, Scanning) – vision-based scanning systems
• Conveyor safety pulls
• RFID bulk scan in shipping/receiving areas
• Hand-held scanners in the receiving process
• Hand-held scanners for reading 2D codes in the receiving process
• Accumulation conveyor/retrofits

• RFID pallet tag reading/writing
• Pallet overhang detection
• Automated pallet storage safety
• Tote fill check and scan
• Empty tote detection
• Pallet detection
• Pallet load profiling

• Pallet transfer car
• ASRS alignment and obstruction detection
• ASRS unit load automation
• ASRS unit load fine positioning

• Vehicle height monitoring
• High bay empty storage confirmation
• RFID bulk scan in shipping/receiving areas
• Forklift anti-collision
• Automatic package/pallet identification from forklifts
• Storage area access control

• Pallet transfer car (cold storage)
• Pallet detection
• ASRS alignment (cold storage)
• Cold storage muting
• Cold storage AGV

• Overhead conveyor collision prevention
• Overhead conveyor safeguarding
• Overhead conveyor guidance and positioning
• Overhang/garment conveyors
• Tote identification and sorting
• Conveyor gapping
• Vertical storage system safety
• Sort conveyor switching
• Vertical storage safety and height detection

• Tote picking and case breakdown
• Picking error detection
• Pick station error-proofing
• Pick quantity verification
• Manual pick verification
• Pick-to-light manual picking stations

Both the front and the back of a hydraulic press brake are protected with a safety camera system and a host/guest system, consisting of a multiple light beam safety device and a safety light curtain to prevent access from the back

The racking station before a robot cell is protected with a safety light curtain. A multiple light beam safety device with a deflector mirror provides access protection behind the racking station. The two sensors are therefore active alternately.

HGVs transport temporarily stored containers from stacks to ship-to-shore cranes. Laser measurement systems determine the position of the HGV below the crane

Packages at a package distribution centre must be assigned to the correct post office. A line scanner reads the information contained in a bar code attached to the side of the package.

Packages at a package distribution centre must be assigned to the correct post office. A line scanner reads the information contained in a bar code attached to the side of the package.

Combustion processes require O2 to react chemically with the fuel. Incineration of waste materials converts the waste into ash, flue gas, particulate, and heat, the latter can be used to generate electric power (waste to energy). O2 is supplied to the combustion process via combustion air. Monitoring the O2 concentration at the boiler outlet is the most important measure for control and optimization of the incineration process.

Our solution:

• Oxygen analyzer ZIRKOR302

Due to environmental protection NOx emissions have to be reduced prior to the release into the atmosphere. In the NOx control process with selective non-catalytic reduction (SNCR) either gaseous ammonia or a mixture of urea and water is sprayed directly into the combustion chamber at temperatures between 900 °C and 1.100 °C. Here NOx molecules react with the ammonia compounds and form nitrogen and water. The NOx emissions are reduced accordingly. In addition to O2 (boiler efficiency), NO is monitored at the boiler outlet for control and optimization of the DeNOx process. With the same system HCl, SO2 and H2O concentrations can be monitored as important control parameters for a subsequent scrubber.

Our solution:

• O2 measurement: Oxygen analyzer ZIRKOR302
• NOx/HCl/SO2/H2O measurement: Analyzing system MCS100E

For the process with selective catalytic reduction (SCR ) gaseous ammonia is fed into the catalyst inlet. The conversion of NOx into water and nitrogen takes place at temperatures between 200 °C and 400 °C. At the inlet of the catalyst NO concentration is monitored to control the ammonia injection. At the outlet of the catalyst NO and NH3 are measured: The NH3 concentration (ammonia slip) indicates the efficiency of the denitrification process while the NO concentration is monitored to ensure compliance with the environmental regulations.

Our solution:

• NO measurement: Gas analyzer GM32
• NH3 measurement: Laser gas analyzer GM700

After the dedusting typically scrubbers are used to remove acidic gases like HCl and SO2. Two scrubbing processes are used, wet scrubbers and (quasi-)dry scrubbers. In wet scrubbers the flue gas is sprayed with an aqueous mixture of water and lime. The gaseous acidic pollutants react with the liquid to form gypsum which can be removed from the waste water to produce drywalls. Using the dry scrubbing process the aqueous solution is replaced by lime powder or a pasty mixture of water and lime. For proper operation control of the dry process continuous monitoring of HCl, SO2 and H2O concentrations is essential.

Our solution:

• Analyzing system MCS100E HW

Pulverized coal is a common fuel in a cement plant. Due to safety reasons, monitoring of CO concentration in coal bunkers and coal mills is an essential issue. Increasing CO concentrations may indicate a smouldering fire and require immediate counter measures. In addition, O2 concentrations provide significant information for coal mills which are operated under inert gas purging: By monitoring the oxygen concentration during the grinding process the entrance of false air into the system can be detected at an early stage. Herewith the danger of explosion or fire can be minimized.

Our solution:

• Analyzing system MKAS Compact

The raw material enters the kiln via pre-heater and pre-calciner. ln the kiln, the sintering process takes place at temperatures up to 1.400 °C. The final product, clinker is leaving the kiln at the opposite end for further processing. Producing high quality clinker is requiring accurate control of energy input: Insufficient heat will leave unconverted lime while excess heat increases fuel consumption and could damage the kiln. Energy input and optimal combustion conditions can be derived from gas analysis data taken from the process gas at kiln inlet. Application task is to continuously monitor the concentration of CO, NO and O2 and in some cases CO2 and SO2 inside the kiln close to the raw material inlet under extreme conditions.

Our solution:

• For gas sampling: Sampling system SCP3000
• For gas analysis: Analyzing system MCS100E HW

In addition to the rotary kiln, modern cement plants are equipped with a multistage cyclone pre-heater and a pre-calciner. The pre-heater is using the excess heat from the kiln and the pre-calciner. Pre‑heating and pre‑calcining of the raw material shorten the sintering process in the kiln, the overall fuel consumption is reduced. Control parameters at the pre-heater are CO, NO, O2 and SO2.

Our solution:

• Analyzing system MKAS with analyzer SIDOR

For environmental compliance the exhaust gases from the production processes have to be dedusted. In addition, the dedusting processes are used for material recovery ( e.g. in the coal mill). Electrostatic precipitators are commonly used for dedusting of the hot exhaust gases from pre-heater, pre-calciner and kiln. For cold exhaust gases (from coal mill, etc.) and for material recovery bag filters are used. In order to detect bag leaks and to ensure compliance with the relevant emission limits SICK dust analyzers are used.

Our solution:

• Dust monitor DUSTHUNTER SP100

For building automation of a perimeter, fence or wall, we distinguish two application areas area monitoring and location indicator systems.
With area monitoring, software in the sensor will manage all monitoring areas. The system signals if intruders are present by releasing the switching output and triggering an alarm whenever an area is violated. This may, for instance, also be triggered by objects or items regardless of whether they are mobile or not.
The sensor uses the measuring data with which it has been provided to determine the location.
When this is done, the devices are set so that small animals, adverse weather conditions or mere passers-by do not trigger any false alarms. Another important feature is that the devices take privacy into account

SICK laser scanners are usually used horizontally for the monitoring of open spaces. If necessary, several reporting levels can be defined for each scanner (standard function). Approach roads and access paths can also be suppressed so that disruptions to pedestrians or road traffic are prevented. As a result, separate, differentiable alarm notifications are generated. Disruptions due to adverse environmental conditions are intercepted first by the scanner ensuring a low rate of false alarms.
Using these separately output signals, the selected area can be monitored and available cameras controlled via a monitor. This has the benefit that monitor images are displayed according to the incident, considerably reducing the onus on security guards. Further benefits include the shape of areas being user-definable and simple installation on buildings.

Laser scanners are usually used vertically for the monitoring of facades. The size of the monitoring areas and the possibility of setting several scenarios (see example of night/day mode) means only a few systems will be required, making protection as effective as it is inexpensive.
The building's floor outline or fence serves as the reference contour. This is constantly inspected by the system to see it remains intact (distance measurement). Deviations in this outline, e. g. due to movements of earth (excavation) in the monitoring area or manipulation of the laser scanner (dismantling) trigger an alarm. The scanners are highly resistant to environmental influences like rain and snow, making the rate of false alarms very low, something which has also been confirmed by TÜV Süd.

With flat roof protection, SICK laser scanners are generally installed directly on the building. This removes the need for expensive installations or attachments on the roof. The monitoring area for the system is set up approx. 30 cm above the ground so that any persons crawling under the alarm zone are detected and registered. The edge of the monitoring area can also be placed slightly above the edge of the roof so that any ladders, for instance, are detected at once. The arrangement of the monitored areas, the choice of object size to be detected and flexibly adjustable response times mean any movement of animals, birds or leaves through the monitored area will not trigger an alarm (filter function).

Areas such as gates and turnstiles can be monitored either using active-switching sensors or a sensor system, which recognizes a special code and then reliably provides access. To do this, either tried and tested bar code reading technology or newer technologies such as RFID with the ISO 14443 standard (special encryption) are available.
Active-switching 2D and 3D sensors and photoelectric sensors, light grids, laser scanners and camera systems (see below) provide a range of options for access detection. The sensor system can be set either so that it recognizes whether an unauthorized person is trying to enter or else how many persons enter a room in order to control parallel systems such as heating, air conditioning or ventilation.

Paintings and sculptures need to be protected from deliberate or accidental vandalism and against theft. Unintentional contact in particular is a challenge for a sensor system as this must be reported without the artistic enjoyment of curators, art lovers or other guests being diminished. The more inconspicuous, precise and reliable protection is, the more this requirement can be met without detriment to the protection. Laser scanners are often used for protection of pictures/walls (vertical) or to protect ceilings/floors (horizontal). For objects such as sculptures, jewelry etc. in wall recesses, light grids have proven to be most appropriate. Fast detection of any interference prevents any “angling” of the object being monitored. Two-dimensional protection is sufficient for paintings but with sculptures, a greater dimensional range needs to be covered. A distance-measuring vision system can also be used for this purpose.