SECTOR GUIDE Sensor Technology Solutions for the Automotive Supply Industry. Meeting the industry s requirements.
Knowledge that matters. Solutions that improve your processes. The optimization of processes in the automotive supply industry is an ongoing task. Global competition and cost pressures are a constant demand. Making every detail an opportunity for increasing efficiency. SICK sensor technology helps to exploit efficiency potential down to the smallest detail. As an independent leader in industrial, safety and auto identification sensor technology SICK has made a lasting contribution to process optimization in the global automotive supply industry for decades. Whether on a large or a small scale, SICK sensor solutions contribute to making the entire production process safer, faster, cost effective and more robust. Hazards and sources of errors are systematically eliminated, individual production steps accelerated. In this way SICK, with its comprehensive factory automation technology competence, provides impressive solutions for all phases of the production process. Everything to keep you and your products leading in the global market. Global presence Complete Sensor Solutions Leader in innovation International Service Solutions E-business Partner Portal 2 AUTOMOTIVE SUPPLY INDUSTRY SICK
Sensor technology benchmarks for the automotive supplier On the following pages you will find an overview of the range of SICK services with solutions for your numerous tasks. Let s talk about how SICK Sensor Intelligence can make your production even more efficient. Together we will identify opportunities for optimization and develop individual solutions for increased competitiveness. COMPREHENSIVE SERVICES Global presence 4 Complete automation 6 Sensor technology highlights 8 International Service Solutions 10 safetyplus 12 Online Partner Portal 14 EXAMPLE SENSOR TECHNOLOGY SOLUTIONS 16 Tire manufacturing 18 Mechanical parts production 21 Bodyshell pre-assembly 24 Parts for interiors 26 Seat production 28 Assembly of small parts 29 Assembly of modules 31 Production of exhaust systems 32 Electronic parts production 33 Network systems 34 SICK AUTOMOTIVE SUPPLY INDUSTRY 3
Global presence. Automation Solutions with no boundaries. In the supply industry a global perspective is of crucial importance. For this reason, SICK has an established worldwide presence. As an independent partner we are always at your side and quickly available. Regardless of where in the world you are. SICK is close to you: with more than 40 national and international subsidiaries, numerous representatives and associated companies. In addition to sales and service, our production and development efforts are decentralized throughout the world. SICK has production facilities, strategically close to our customers in Germany, Italy, Sweden, Japan and the USA. In this way, we are close to the automotive industry, close to our partners. As an innovative automation partner to our customers, we regard it as our duty towards our own corporate image and our customers: to be always a step ahead of current technological developments around the globe. Profit from our worldwide presence. Always and everywhere. 4 AUTOMOTIVE SUPPLY INDUSTRY SICK
Right round the globe Europe Austria Belgium Czech Republic Denmark Finland France Germany Great Britain Hungary Italy Luxembourg Netherlands Norway Poland Portugal Romania Russia Slovakia Slovenia Spain Sweden Switzerland Turkey America Argentina Brazil Canada Chile Mexico USA Venezuela Africa South Africa Asia China India Indonesia Japan Korea Malaysia Singapore Taiwan Thailand Australia GLOBAL LOGISTICS AND SUPPORT The international SICK logistics center shortens delivery times and reduces service costs and stock-holding costs. We bring components and spare parts at the right time, in the right place to you. Profit from our logistics! For service a worldwide presence is vital. With subsidiaries and representatives around the globe, we are on-site where you need us. SICK AUTOMOTIVE SUPPLY INDUSTRY 5
Complete Automation Solutions. Intelligent sensor technology and perfect networking assure success. SICK recognized the key role of sensor technology in plant automation early on and developed application- oriented sensor products. These innovative products became sensor solutions which are more than simple sensing elements. Innovative Sensor Intelligence after all is what we are striving for: Integrated systems which include safety, control and monitoring functions. A perfect example is our UE1000 series of safety network solutions: Solutions for machines and systems with a high degree of connectivity. A SICK innovation from the Industrial Safety Systems division. In addition, our development continues in the divisions of Industrial Sensors and Auto Ident. To provide our customers with state-of-the-art technology. With Sensor Intelligence your processes achieve a degree of optimization which was inconceivable a few years ago. And you hold all the aces: quality, efficiency and clear production processes. Combine safety, control and monitoring functions into one integrated working solution with systems, products and services from SICK. INDUSTRIAL SENSORS Encoders, ultrasonic sensors, inductive, capacitive and magnetic proximity sensors as well as magnetic cylinder sensors, photoelectric switches, contrast scanners and luminescence scanners, color sensors, fork sensors, light grids, distance sensors, data transmission systems, vision sensors, position finders and light section sensors. 6 AUTOMOTIVE SUPPLY INDUSTRY SICK
INDUSTRIAL SAFETY SYSTEMS Photoelectric safety switches, safety light curtains, safety laser scanners, safety camera systems, safety switches, safety controllers, safety relays and safety software. The range of services provided includes commissioning, safety inspections, repairs and device exchange service, stoptime measurements, technical consultation, education and training. AUTO IDENT Stationary 2D code scanners and barcode scanners, hand-held scanners for mobile and stationary use, omnidirectional barcode reading systems, indoor and outdoor laser measurement systems, evaluation electronics, bus interfacing technology, software tools, engineering. SICK AUTOMOTIVE SUPPLY INDUSTRY 7
SICK-highlights for the automotive supply industry. Milestones in sensor technology. Technology does not evolve on its own. Innovative solutions are created only when people look beyond the known and familiar, create new ideas and nurture them to market maturity. That is the SICK way! SICK investment in research and development has always been above average. These aspects power sensor technology development and our worldwide success. The results are impressive: sensor technology milestones that have time and again opened up new opportunities for process optimization, especially in the automotive supply industry. Innovations that are worthy of the SICK brand and that have made a significant contribution to the technological progress in their sector. What began in 1950, with the first photoelectric switch suitable for practical use, is still a long way from over with the latest generation of milestones laser scanners, light curtains, smart cameras and image code readers. Rely on the leader in innovation for all your sensor technology. With SICK your production will set the benchmarks for the entire industry. LEADING IN EVERY DISCIPLINE IMPROVED EFFICIENCY AND QUALITY WITH CAMERA TECHNOLOGY The real world has three dimensions! For this reason conventional 2D cameras are always a compromise if height matters. The IVC-3D is the first smart camera in the world that checks all three dimensions and provides you with unmatched results, e. g. during quality control on brake pads. Protection Collision prevention Navigation Measurement Positioning Identification Sorting Picking Integration 8 AUTOMOTIVE SUPPLY INDUSTRY SICK
COMPLETE TRACEABILITY OVER THE ENTIRE LOGISTICS CHAIN WITH 2D CODE READING SYSTEM Continuously increasing product and process variety inevitably increases manufacturing complexity. Powerful sensor systems can meet these challenges. They ensure maximum process reliability and at the same time complete traceability over the entire production pro cess. ERROR PROOFING, THE BASIS FOR EFFECTIVE QUALITY ASSURANCE 2D cameras are indispensable during the inspection of parts in the production of automotive parts. Where normal sensors reach their limits, the cameras detect defects in continuous production and logistics processes and in this way contribute to a strong image on quality. V4000 PRESS BRAKE SAFETY AND EFFICIENCY WITH A COMMON DENOMINATOR SICK First in industrial safety. SICK systems provide a common denominator for safety and efficiency in production. A complete component, controller and service portfolio always offers the right solution: from the risk analysis during the design phase to after-sales service. SICK AUTOMOTIVE SUPPLY INDUSTRY 9
Service for the life of a machine. From planning through operation to retrofitting: International Service Solutions Safety starts with the installation of state-of-the-art SICK sensor technology. And continues through the life of the machine Safety with Sensor Intelligence after all is a continuous process which remains crucial throughout the whole life cycle of a machine or plant: From planning through operation to retrofitting. With SICK International Service Solutions you benefit at all stages from the application knowledge and experience of the market leader in industrial safety. Manufacturer with official inspection accreditation DESIGN The work of SICK safety experts starts as early as the design phase. A customized, cost-optimized safety solution is produced jointly with you. We support you during the risk analysis, e.g. with our software Safexpert to ensure that all relevant regulations are met. In this way we help to prevent avoidable additional costs. A shorter time-to-market becomes feasible. COMMISSIONING Due to skilled support during commissioning, the machine runs safely from the start. As a result run-up problems are prevented from the inset and prompt availability is guaranteed. Worldwide product support ensures maximum machine life and availability. OPERATION With customized service contracts you will ensure system availability. Periodic inspections ensure a high safety standard. You will also profit from a 24-month guarantee and the repair and exchange service. If at some point an emergency should occur, SICK service will be on-site quickly and ensure that operation can continue as quickly as possible. 10 AUTOMOTIVE SUPPLY INDUSTRY SICK
Safety during the whole machine life cycle. For more accident prevention and increased efficiency. SICK INTERNATIONAL SERVICE SOLUTIONS UPGRADE SERVICES SICK INTERNATIONAL SERVICE SOLUTIONS MAINTENANCE REPAIR MODI- FICATION PLANNING ENGINEERING DESIGN MACHINE LIFE CYCLE COMMIS- SIONING SICK INTERNATIONAL SERVICE SOLUTIONS APPLICATION SUPPORT SICK INTERNATIONAL SERVICE SOLUTIONS COMMISSIONING SUPPORT INITIAL INSPECTION SICK INTERNATIONAL SERVICE SOLUTIONS PERIODIC INSPECTION OPERATION SICK INTERNATIONAL SERVICE SOLUTIONS STOPTIME MEASUREMENT During the whole machine life cycle SICK INTERNATIONAL SERVICE SOLUTIONS TRAINING & EDUCATION SICK INTERNATIONAL SERVICE SOLUTIONS PRODUCT SUPPORT SICK AUTOMOTIVE SUPPLY INDUSTRY 11
safetyplus from SICK. Complete safety, improved performance. SICK sets standards: with the most comprehensive safety portfolio in the world, and with the crucial Plus for all your challenges! safetyplus covers the entire range from the Industrial Safety Systems division, and provides assistance to anyone who does not want to do without the technically feasible any more than without the financially desirable. With safetyplus we accompany you during all phases of the machine life cycle and give you the certainty of always being on the safe side. SAFETY COMPETENCE SICK supports you: from the first safety risk assessment to the evaluation of potential hazards, and accompanies you from the design phase for machines and systems to operation support! On the topic of safe dialog between man and machine, OEMs and operating organizations benefit from our knowledge of worldwide safety standards. Providing you with maximum legal protection. OPEN SYSTEMS FOR YOUR MACHINES AND SYSTEMS! SICK develops innovations and solutions that can be easily integrated into any system architecture. The philosophy of open systems becomes particularly apparent in our safety controllers: they are designed to ensure easy integration and provide numerous connectivity options. For you this situation means maximum security of investment! 12 AUTOMOTIVE SUPPLY INDUSTRY SICK
Industrial Safety Systems. Made by SICK. MORE INTELLIGENCE FOR THE SMOOTH OPERATION OF YOUR BUSINESS! The use of intelligent control components in combination with sensor technology with dialog support provides an important opportunity for increased productivity and cost-effectiveness. Customized SICK solutions provide application flexibility and ensure you always have safety under control. MORE SERVICE FOR CUSTOMIZED SAFETY! The quality of our products is the result of close collaboration with our customers, many of whom have been working with us for years. Consultation, engineering/planning, inspection services, training are part of our comprehensive service repertoire: more than 4000 employees from more than 40 subsidiaries in more than 20 countries are also always available to help you! SICK AUTOMOTIVE SUPPLY INDUSTRY 13
Work even more efficiently online. www.mysick.com Your sensor technology Partner Portal. When efficiency and rapid processing are as important in every detail as they are in the automotive supply industry, the online portal is a must! At www.mysick.com you will find comprehensive e-commerce tools and information for your sensor technology planning: complete order management from the availability check, through quotations and terms and conditions, to order placement and status. With the individual assignment of user permissions, the SICK Partner Portal will support your workflow. Simple online access to application examples as well as the download of technical data, drawings and graphics. All the information you need for planning, at your fingertips. Plan your sensor technology online in the SICK Partner Portal. Clear: using the Products, Information and My account menus you will find everything for your sensor technology planning. Available 24 hours: Regardless of where you are in the world or when you need to know something. At www.mysick.com everything is a click away. Safe: your data are password protected and can only be seen by you. With individual user administration you can define who is allowed to see which data and perform which actions! www.sick.com/productfinder The product finder enables you, based on its specification, to find the right device from our large portfolio of factory automation products. www.sick.com/applicationfinder With the application finder you can select an application description for a specific problem, sector or product group. www.sick.com/literaturefinder In the documentation finder you can access all publications, e.g. operating instructions, technical information, customer magazines and other literature related to SICK products. 14 AUTOMOTIVE SUPPLY INDUSTRY SICK
YOUR ADVANTAGES IN THE SICK PARTNER PORTAL Order immediately online! Your work will be even more efficient online User administration supports your workflow Product availability is displayed immediately All processes are accelerated significantly, e. g. price queries, quotations, orders Find products, applications, circuits and accessories even faster Product search and product information, only a click away! All processes at a glance: product search, quotation, order status, etc. Exclusive download features: technical data, drawings, graphics, etc. Price and availability finder: fast and easy access to the price and delivery information. Quotation request: you can enter a reference number for your quotation. The quotations are available online. Every quotation will be confirmed by e-mail. Online ordering: you can complete the ordering process in a few steps. SICK AUTOMOTIVE SUPPLY INDUSTRY 15
SICK provides more than sensor technology solutions to all sectors of automotive parts production. Discover step by step how SICK Sensor Intelligence makes processes in and around your automotive parts production faster, more efficient and safer. Based on selected applications that we have illustrated as examples, we will highlight the wide range of options provided by our intelligent sensor solutions. See for yourself and discover your potential for optimization. We will of course assist you. The applications shown in the following are only in a schematic form. The selection of devices, their arrangement and mounting must be adapted to the task and the requirements of the site where the devices are used, especially in the safety technology sector. The illustration of the applications, the product features and the technical data stated do not represent any form of warranty. 16 AUTOMOTIVE SUPPLY INDUSTRY SICK
FOCUS 1 18 TIRES FOCUS 2 21 MECHANICAL PARTS FOCUS 3 24 BODYSHELL ASSEMBLY FOCUS 4 26 INTERIOR TRIM FOCUS 5 28 SEATS FOCUS 6 29 SMALL PARTS FOCUS 7 31 MODULES FOCUS 8 32 EXHAUST SYSTEMS FOCUS 9 33 ELECTRONIC PARTS SICK AUTOMOTIVE SUPPLY INDUSTRY 17
Focus 1: Tires The LMS400 laser measurement system measures the height and width of the rubber mass above the hopper rollers. The measurement system provides a constant amount of material via a controller. The result is a web of material of constant width without any gaps. Two pairs of OD Max distance sensors measure the thickness of the web of rubber after the rollers using the differential method. They control the hopper rollers to ensure the nominal thickness is maintained. Extruded tire treads are fed to a tire building machine via a loop control system. Here two possible ways of continuously measuring the loop are shown: a) using a modular MLG PRO- FIBUS light grid that measures the sag on the loop from the outside and b) using a DT20 distance sensor that measures the distance inside the loop. The loop is continuously adjusted using the measured values from one of these sensors and the measured values from the DGS60 encoders bolted to the axles driving the system. The IVC-2D vision camera is used for quality assurance. It checks the tread for any holes, inclusions, bubbles or other defects. 18 AUTOMOTIVE SUPPLY INDUSTRY SICK
Protection of two hazardous areas using only one S3000 safety laser scanner on a tire building machine. The laser scanner s protective field always monitors the system station in which there is a dangerous movement, in this case the rotating movement for erecting the tire. With the spindle rotating slowly, the worker manually positions the individual layers of the tire in the other station on the winding device and then starts the assembly of the tire using the foot switch. At the same time the protective and warning field in front of this station is activated. If the protective field is interrupted, the dangerous movement is stopped. The signals are linked via a UE4470 flexible safety controller using external IP-67 UE4450 safety remote I/O. All-round protection of a mobile tire building machine using only two S300 safety laser scanners. In this way the slowly moving machine is protected on all four sides against collisions with people, other vehicles and material on the floor. The protective field (red) With this safety concept low cost wiring and flexible expansion of the system are possible. and warning field (yellow) for the two S300 are fixed. They are adapted to the velocity of the AGV and ensure collision-free movement. This mobile tire building machine for truck tires is protected in both directions of movement using S3000 safety laser scanners. The size of the protective field (red) and warning field (yellow) is adapted dynamically to the velocity. In case of a change in the direction of travel, the protective and warning fields are switched. In vulcanizing presses the so-called green tires take on their final shape and profile. The worker retrieves the tire from a truck using a lifting device and places it in the female mold in the press. The tire is pressed against the mold pneumatically and cooked. The accesses to the presses are protected here using three different safety sensors: a) using M4000 multiple light beam safety devices, b) using two WSU/WEU26 single-beam photoelectric safety switches and c) using two L400 single-beam photoelectric safety switches. The M4000 and the WSU/WEU26 are connected to a UE470 compact safety controller that evaluates the press control signals such as top dead center (TDC), bottom dead center (BDC) and run-on monitoring, as well as the signals from the foot switch and emergency stop button. The L400 are connected to a UE401 evaluation unit. SICK AUTOMOTIVE SUPPLY INDUSTRY 19
Tires The ICR890 camera system identifies tires prior to placing in store. The barcode to be read is fitted to the bead. The identification is used to allocate the right tires to the right storage location. The information read can be processed in a central computer for quality assurance. The reading system is triggered by two VL18 photoelectric reflex switches. Tire identification using the OPS890 barcode reading system. The system comprises eight CLV490 line scanners arranged to reliably detect the barcode on the tire bead. The reading system is triggered by two WL18 (A) photoelectric reflex switches that are arranged in an X-shape in the reading zone to reliably detect the tire. Two further WL18 (B) photoelectric reflex switches 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. The WLR1 photoelectric reflex switches control the insertion of the tires in a store. The devices are specially designed for socalled accumulating conveyors. They are equipped with solenoid valves. The conveyor is divided into segments at the end of which there is a WRL1 with a reflector mounted opposite. The internal logic in the devices ensures a controlled flow of product so that the movement of the tires is started or stopped at defined segments. 20 AUTOMOTIVE SUPPLY INDUSTRY SICK
Focus 2: Mechanical parts Gearwheels are pressed onto gearbox shafts in these presses. The hazardous area is protected using a C4000 safety light curtain in combination with a UE470 compact safety controller. The gearbox shafts are automatically moved into the press on carriers. An IQ40 inductive proximity sensor detects the carrier and triggers a stop signal for the transport as well as a signal for exact positioning. The press operates in single break PSDI mode: the worker places the gearwheel on the shaft. In the process, the worker interrupts the light curtain s protective field. As soon as the worker leaves the protective field again, the machine cycle is started automatically. The two doors for the carrier inlet and outlet are protected using T4000 Compact safety switches. If a door is opened, a stop command for the dangerous movement on the press is triggered. All press control signals such as top dead center (TDC), bottom dead center (BDC) and brake monitor as well as the signals from the door protection and the emergency stop button are evaluated by the UE470. A reset switch is required for the first machine start, to reset the restart interlock if the protective field was interrupted during a dangerous movement, or when the monitoring time of 30 s has been exceeded. Two ball joints with slightly different shank diameters are fitted to a suspension system. They must be identified and sorted. For this purpose the joints are fed to an inspection station via a handling robot. In this inspection station an OD Max displacement sensor measures its distance from the item inspected with very high accuracy and in the process reliably determines the diameter of the item. An IM8 inductive proximity sensor signals the presence of a ball joint to the controller. SICK AUTOMOTIVE SUPPLY INDUSTRY 21
Mechanical parts An LMS400 laser measurement system is mounted on the end effector on the loading and unloading robot. This device moves with the end effector arm over the racks with the workpieces and in this way generates a threedimensional image of the products loaded. All relevant data are sent rapidly and precisely to the robot via an evaluation program such that the robot can correctly position its end effector and remove the parts at high speed. The compact IVC-3D smart camera checks the brake pads. Three inspection tasks are performed at the same time: the surface structure, the height of the pins and the mounting position of the metal springs. All tasks that can be straightforwardly and reliably solved using 3D images, unlike image processing using gray scales. A WT9-2 photoelectric proximity switch triggers the camera. 22 AUTOMOTIVE SUPPLY INDUSTRY SICK
An OD Hi displacement sensor checks the correct seating of a spacer: it measures the distance to the spacer and compares the value measured to a setpoint. It can do both: detect the presence of parts and also measure their position precisely. An IQ40 inductive proximity sensor detects the carrier moving into the inspection station. It triggers a stop signal for the transport and sends a signal to the positioning device: two conical pins move from below into conical holes on the carrier and in this manner align the carrier precisely in relation to the OD Hi. The pins are moved using pneumatic cylinders. The two positions for the pistons are each detected using an MZ2Q magnetic cylinder sensor. The data on a finished cylinder head are applied directly to the housing in a matrix code using the dot pinning method. For production control this code is read using an IT6320 direct part marking hand-held scanner and transmitted wirelessly via a Bluetooth TM class 2 module to the quality management system. The refined exposure concept in this handheld scanner can be individually adapted to the application. The ICR840 code reader reads the twodimensional 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. The OD100 distance sensor checks for the correct position of the camshaft prior to fitting the timing chain. SICK AUTOMOTIVE SUPPLY INDUSTRY 23
Focus 3: Bodyshell assembly Hazardous point and hazardous area protection in front of a rotating table using C4000 safety light curtain and S3000 safety laser scanner. The C4000 stops the rotary movement of the table if a worker reaches into its protective field. Its height prevents reaching over. The S3000 is used for area guarding of a non rectangular area. The protective field of the S3000 can be programmed as required over a radius of 7 m and can therefore be adapted to the specific spatial situation. All safety sensors for a workstation including emergency stop buttons and sensing elements can be installed on the UE4150 safety remote I/O for PROFIBUS and accessed over the bus using an address. All devices connected can be analyzed and data displayed. Simple installation due to pre-programming and lowcost expansion of a system is possible. Parts check using a WT12L laser photoelectric proximity switch. The switch signals that the part has been ejected from the press tool and helps prevent damage to the tool due to double loading. Two OD Max displacement sensors determine the exact thickness of the sheet metal and report thickness variations and double sheets. In a downstream controller the measured values from the sensors are evaluated using the difference method. In this way, on the one hand the correct sheet metal thickness is checked, and on the other hand damage to tools in the subsequent processing station is prevented by the detection of double sheets. 24 AUTOMOTIVE SUPPLY INDUSTRY SICK
Prior to further processing, pipes are checked for correct shape. Two OD Max displacement sensors in this inspection station measure the diameter of the pipes using the differential method. The evaluation is per formed in a controller. The WL18 photoelectric reflex switch triggers the measurement process and at the same time signals to the holding device (not shown in the illustration) the presence of a pipe: the device closes and holds the pipe in a stable position for a time. The hazardous point in the front of this guillotine is protected using a C4000 safety light curtain. Any interruption in the protective field stops the machine s dangerous movement. The rear of the guillotine is protected against access using M2000 A/P multiple light beam safety device. This safety device comprises a sender/ receiver unit in one housing and a deflector mirror. Only the sender/receiver unit requires electrical connections. Any interruption of the light beam stops the machine s dangerous movement. The V4000 safety system safeguards access to the hazardous point on a press. Sender and receiver are mounted on the top tool and define a protective volume directly underneath the punch; the protective volume moves with the punch. The V4000 sends a signal for the machine to stop if an intrusion in the safety volume is detected (e.g. a finger or a hand). The V4000 can be programmed in different modes to allow for bending boxes or to accept the presence of a back gauge. The two doors prevent access from the side. The doors are monitored electronically using RE4000 safety sensors. The access protection on the rear of the press is accomplished using a host/guest system of a vertically mounted M2000 multiple light beam safety device and a horizontally arranged C2000 safety light curtain for point-of-operation guarding. Entrance into the hazardous area stops the dangerous movement of the press. SICK AUTOMOTIVE SUPPLY INDUSTRY 25
Focus 4: Interior trim Parts inside doors are assembled on an assembly station. The assemblies are then checked from above and below using an automatic quality assurance inspection machine for completeness and correct arrangement of the parts fitted, as well as for correct colors. The automatic inspection machine can be accessed from two sides to enable the worker to operate ergonomically, quickly and without barriers. Both sides are protected with S300 safety laser scanners. Here the assembly to be inspected (see above) and the individual inspection sensors (for a clearer overview without the jig) are shown: Two CVS1 color vision sensors inspect the colors of the fabric and the door trim from above. Two WT9L laser proximity switches check for the presence of switches for the window winder and the loudspeaker trim. One WT9L laser proximity switch detects the drive for the window winder from below. Two further WT9L and two inductive IM08 proximity sensors signal the presence of fastenings. All sensor signals are evaluated. In case of NOK parts (not OK) the necessary re-work is indicated directly to the worker. 26 AUTOMOTIVE SUPPLY INDUSTRY SICK
Each compartment on a shelf system for small parts is equipped with a PLG Pick- 2Light light grid on the side where parts are drawn. The green job light indicates to the worker the compartment from which a part is to be taken: worker prompting (also called pick to light or poka-yoke). If the worker accidentally reaches into the wrong compartment, the mistake is indicated optically and acoustically. The shelf system is re-stocked from the rear. The worker reads the barcode on the box and the compartment with the aid of an IT3800 hand-held scanner. If the green indicator over the shelf illuminates, the new parts are in the right place. WT18 photoelectric proximity switches with a Job LED are fitted above the compartments on this shelf system for small parts. The illumination of the Job LED indicates to the worker the compartment from which the next part is to be taken: worker prompting. If the worker accidentally reaches into the wrong compartment, the mistake is indicated using optical and acoustical indicators. After the assembly station for air condi tioner switches, the IVC-2D smart camera checks for completeness and also checks the symbols applied for correct position. A WL12 photoelectric reflex switch triggers the camera. Faulty assemblies are ejected. The program for handling the task is quickly and directly generated with the aid of the user-friendly Windows -based configuration software IVC Studio. The compact camera does not require any evaluation unit. SICK AUTOMOTIVE SUPPLY INDUSTRY 27
Focus 5: Seats Two WT9L laser proximity switches and four IM12 inductive proximity switches control the end effector on a robot for picking up a part for a seat. MTZ1 magnetic cylinder sensors detect the position of the piston in the pneumatic cylinders that are used to close or open the end effector. All sensors are connected to the controller using an IP-67 distributor. Traps and pins are welded to side pieces for seats on the rotary table. The robot places the parts for the seat in the clamping devices on the rotary table. INOX series IM18 inductive proximity sensors confirm the presence of the parts; the clamping device then closes and the table rotates 180 to the worker. The worker places the straps and pins on the parts for the seat. The WT12L laser photoelectric proximity switches signal the presence of the straps and pins. The rotary table is protected by a system comprising two C4000 safety light curtains connected in series. The system is connected via the UE4150 PROFIsafe safety remote I/O to a safety controller. The vertical mounting of the light curtain here does not provide adequate safeguarding since a person could possibly stand behind the light curtain. To protect the worker from this risk, a second C4000 is mounted horizontally underneath the vertical light curtain. The safety lights curtains as well as the emergency stop buttons and sensing elements are connected via a UE4150 safety remote I/O to the PROFIsafe network. 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 measuring devices 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 top DME5000 provides the values for the seat inclination. The CLV450 code reader with oscillating mirror identifies the seat and passes the data to a central computer. The WT23 photoelectric proximity switch triggers the barcode reader. 28 AUTOMOTIVE SUPPLY INDUSTRY SICK
Focus 6: Small parts In this assembly station, rotors are inserted in electric motors for injection pumps by a robot. The pumps are moved into the assembly station on carriers. An IM12 inductive proximity sensor detects the carrier, triggers a stop signal for the transport and sends a signal to the positioning device: two conical pins move from below into conical holes on the carrier and in this way align the carrier precisely. The pins are moved using pneumatic cylinders. The position of the piston is detected by MZ2Q magnetic cylinder sensors. Two OD Hi displacement sensors arranged offset by an angle of 90 measure the position of the rotor axle. They send their measured values to a PLC, the robot adjusts the position until the stipulated tolerance limit for the correct position of the axis is met in each direction. The robot then receives the signal to insert the rotor. Reflections on the shiny rotor axle have no effect on the reliability and precision of the measurement due to the CMOS detectors used in the OD Hi. Straps on sheet metal parts are bent in a small hydraulic press. The parts are inserted and removed cyclically by hand. The hazardous point is protected by a C4000 Micro safety light curtain in conjunction with a UE470 compact safety controller to which all relevant safety signals are connected. The C4000 Micro has a particularly compact design. The press is operated in the double break PSDI operating mode: the machine cycle is automatically restarted after the protective field is cleared following the second interruption (take workpiece from the tool, insert new workpiece). A reset switch is to be actuated: the first time the machine is started, if the protective field has been interrupted during a dangerous movement, or to acknowledge a restart after a duration of more than 30 s. SICK AUTOMOTIVE SUPPLY INDUSTRY 29
Small parts 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 switch 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. The end effectors are actuated using pneumatic cylinders. MZT6 magnetic cylinder sensors poll the position of the piston in the cylinder. Once both rings are fitted, the robot replaces the nozzle on the conveyor belt where an ICR840 code reader reads the two-dimensional code applied by laser (direct part marking) and transmits the information to a central computer for quality assurance. The CVS3 vision sensor checks the correct position of conical sealing rings before an assembly station. The CVS3 is triggered by an WLL170T photoelectric switch with fiber optic cables. Incorrectly aligned rings are ejected. 30 AUTOMOTIVE SUPPLY INDUSTRY SICK
Focus 7: Modules After the assembly of radiators, a CVS1 color vision sensor checks for the presence of side pieces. The sensor counts the pixel in its field of view and compares the result with the number of pixels taught for a correct radiator. Variations result in the ejection of the radiator inspected. The evaluation of a large area as well as a large scanning distance and depth of field minimize the effort for object movement. A WT18 photoelectric proximity switch triggers the sensor. The ICR840 2D code reader identifies batteries of the same size but different capacity on a conveyor belt so that they can then be placed correctly sorted in mesh crates. The batteries are fitted with high-gloss labels printed with 2D codes. The special advantages of the ICR840 code reader here are the reliable reading of the code as well as the automatic detection of every code independent of its position on the battery. The ICR840 is integrated directly into an Ethernet network. In this robot cell the top and bottom of a fuel tank are fitted, i. e. the robot folds and forms the seam between the parts. The access protection for the cell is provided by a C4000 safety light curtain. As it is possible to stand behind this device, further safety devices are required: Two S300 safety laser scanners fitted diagonally to the jig complete the protection. On the robot, IN4000 safety switches monitor the movements of axes 1 and 2 such that, in addition, people who are (incorrectly) behind or directly beside the robot are protected. In front of the robot a further S300 safety laser scanner monitors the robot s working area. If a worker enters or reaches into this area while the robot is in operation, a system emergency stop is performed. All safety sensors as well as emergency stop buttons and sensor elements are connected via UE4450 safety remote I/Os to the UE4470 flexible safety controller and the robot controller via a safety network. Cabling is reduced significantly. Due to the simple programming of the UE4470 flexible safety controller the commissioning time is reduced. SICK AUTOMOTIVE SUPPLY INDUSTRY 31
Focus 8: Exhaust systems On these hydraulic presses, C4000 Standard/ Advanced safety light curtains combined with the compact UE470 safety controller and T4000C safety switches safeguard the side access doors to the hazardous points. All press control signals such as top dead center (TDC), bottom dead center (BDC) and brake monitor, as well as the signals from the door protection and the emergency stop button are evaluated by the UE470. Muffler and exhaust pipe are welded together on an assembly table. For this purpose both parts are placed in position in a clamping device. The muffler is held in position using a pneumatic cylinder. An MZ2Q magnetic cylinder sensor indicates the position of the piston to the controller: clamping device open or closed. The exhaust pipe is held in place by a second clamping device (not shown in the illustration). The presence of the strap on the pipe is checked by a WT2 photoelectric proximity switch. This switch is immune to interference from critical backgrounds. If the switch has detected the strap, the pipe is in the correct position and is at the correct angle in relation to the muffler: the welding process can start. In this pipe bending machine, DGS6Q incremental encoders or motor feedback systems with a HIPERFACE interface supply the signals for the product-dependent control of the pipe feed, the pipe rotation and the pivoting movements of the bending head. The dangerous bending zone on the machine is protected with an S3000 Advanced safety laser scanner, the sides of the machine are protected with an S300 safety laser scanner. Protective and warning fields are configured in the S3000 and S300 safety laser scanners as a function of the product to fit the dangerous movements of the bending head or the pipe to be bent. These fields are switched by the machine controller. The safety hood on the pipe bending machine is protected using T4000 safety switches. The machine is stopped if the hood is opened. 32 AUTOMOTIVE SUPPLY INDUSTRY SICK
Focus 9: Electronic parts Populated printed circuit boards are fed to an automatic component placement machine. An ICR840 matrix code scanner on the infeed identifies the printed circuit boards and, via the machine controller, defines to the automatic machine the components that must be fitted to the boards. The WT4 photoelectric proximity switch triggers the code reader. An i14 Lock safety locking device secures the sliding door on the automatic component placement machine. To open the door it is necessary to actuate a control switch via which the solenoid operating voltage is applied and the locking solenoid released. Only when the dangerous movements in the automatic machine have stopped does the safety locking device allow the door to be opened. Fuse carriers are automatically filled with fuses with four different ratings. Each of the four ratings has a color code. The order, the number and the rating of the fuses are defined via a PLC. A CS8-4 color sensor checks at high speed in front of the automatic component placement machine for the entry of the fuses and indicates the colors to the controller. If the information defined by the PLC and the colors detected do not match, the related fuse is ejected. The four colors are taught once by teach-in. The tolerance can be set to coarse or fine. SICK AUTOMOTIVE SUPPLY INDUSTRY 33
SICK sensor systems. Powerful, flexible and open for all system worlds. CLV420 barcode scanner CDB400 connection module for barcode scanner IT5620 hand-held scanner OPS400 OMNI portal scanner CLX490 omnidirectional barcode reading system CDM400 connection module for barcode scanner DME5000 distance sensor IVC-2D Industrial Vision Camera MLG automation light grid ATM60/90 absolute multiturn encoder AS-i field bus module IO-LINK THE NEW SENSOR/ ACTUATOR INTERFACE Connection module IO-Link Passive elements become active process participants that communicate with the control level to independently signal states and faults. With this central and continuous complete indication of all functions to the sensor level, more efficient system operation is possible. W12-3 photoelectric switch W27-3 photoelectric switch IM18 inductive proximity sensor MLG automation light grid W12-2 photoelectric switch W27-2 photoelectric switch 34 AUTOMOTIVE SUPPLY INDUSTRY SICK
CONTROL FLEXIBLY WITH OR WITHOUT SAFETY PLC SICK safety controllers solve safety tasks flexibly and cost-effectively. Only as much control technology as necessary. The system can be adapted and expanded easily from simple solutions to the more complex, nested safety functions. A significant plus for efficiency! FDT/DTM TECHNOLOGY Standardized style guide : different device tools can be used with the same philosophy. Central data storage: the configuration data from the individual device manufacturers, the DTMs (Device Type Manager), are saved centrally in the FDT (Field Device Tool. Common access point: only the FDT establishes the connection to the device at the field level. OPC SERVER Status and diagnostics directly at the HMI (Human Machine Interface) and over the company network Remote maintenance from any location, all the way into the protective field Information management: configuration backup saved centrally Active-X enables protective fields to be displayed in the OPC client with just a few mouse clicks. Flexible safety controller SICK sensor technology from the Industrial Sensors, Industrial Safety Systems and Auto Ident divisions can be used on almost all system platforms. The options available for integration in the controller technology based on worldwide standards make every solution a future-proof investment. PROFIBUS, PROFIsafe PROFINET DeviceNet, DeviceNet Safety Ethernet, Ethernet/IP AS-i, AS-i Safety at Work SICK CAN scanner network AS-i Safety at Work Slave UE4200 Safety network solutions DeviceNet Safety Safety network solutions PROFIsafe Safety network solutions DeviceNet Safety C4000 safety light curtain Safety switch S3000 safety laser scanner M4000 multiple light beam safety device Safety positioning switch SICK AUTOMOTIVE SUPPLY INDUSTRY 35
RANGE OF EXPERTISE Industrial Sensors Industrial Safety Systems Auto Ident Analyzers and Process Instrumentation Our complete range of sensors pro vides answers to suit any application in the field of automation. Even under rugged ambient conditions objects are reliably detected, counted and positioned in respect of their form, location and surface finish, as well as their distances established with pin-point accuracy. Comprehensive safeguarding of both personnel and machinery! As specialists in Sensor Technology, SICK develops and manufactures pioneering products for providing protection in hazardous zones, dangerous locations and for safeguarding access points. By providing services, which encompass all aspects of machine safety and security, SICK is setting new standards in Safety Technology. Whether the tasks involve identification, handling, classification or volume measurement, innovative Auto Ident systems and laser measuring systems function extremely reliably, even under rapid cycle times. They conform to the latest Standards and can be simply and speedily integrated in all industrial environments and external applications. System control, maintaining setpoints, optimising process control and monitoring the flow of materials the instruments and services for Analysis and Process Measurement, supplied by SICK MAIHAK, are setting the standards for these applications in terms of Technology and Quality. 8011796/2006-11 MRH/FD Printed in Germany (2006-11) Subject to change without notice 00 WB int27 Worldwide present with subsidiaries in the following countries: Australia Belgium/Luxembourg Brasil Ceská Republika China Danmark Deutschland España France Great Britain India Italia Japan Nederlands Norge Österreich Polska Republic of Korea Republika Slovenija Russia Schweiz Singapore Suomi Sverige Taiwan Türkiye USA/Canada/México Please find the detailed addresses and more representatives and agencies in all major industrial nations at www.sick.com SICK AG Waldkirch Germany www.sick.com