Customer magazine "Contact". 2010

THE TECHNICAL AND CUSTOMER MAGAZINE
Ready for the future!
Versatile safety technology
according to new European standards.
Can you see the light?
Our smart camera family
is growing and thus ideally prepared
for the future.
Edition No. 06
04/10
Page 02
Editorial
“Good preparation keeps you safe.”
A clever man once said: “He who thinks of tomorrow today
cannot easily be surprised the day after tomorrow either”. It is
this anticipatory view that has characterized Leuze electronic’s
specialists from the very beginning. It ensures that our customers are ideally prepared for the future.
This is reflected in the most recent developments regarding
safety at work. Not only were the new standards EN ISO 13849
and IEC 61508 introduced, but the validity of the old standard
EN 954-1 was also extended by two years. Nevertheless:
postponed is not abandoned. Machine manufacturers rightly
deal with this subject quite intensively. This leaves two years to
make clever use of these changes.
We have developed our new products according to the future
standards and have adapted and recertified proven existing
products where necessary. We don’t just support you through
competent advice, but can also offer sustainable solutions with
our products. Our seminars, workshops and training (“Machine
Safety Services”) complement this offer.
It becomes apparent in the validation of safety chains that a
great deal of attention is paid to the mathematics. Other
important aspects surrounding the sensor should not miss out,
however. For example, numerous new features offer the
opportunity to reduce cost during the life cycle of a machine
and to increase efficiency.
Our most recent example in this context is the new Multiple
Light Beam Safety Device MLD—the first three-beam
transceiver for access guarding - high-quality safety technology
at minimum cost. The concept of configuration via fixed wiring
has been advanced consistently in this case and permits
installation without special configuration tools.
Read about other examples in this issue that generate a high
customer value. Further issues will follow.
Dr. Holger Lehmitz
Head of the Safety Systems Division
Page 03
Contents
04
Fast reading of
moving codes
12
Premounted Safety Sensor Sets
simplify the setup of access guarding
Smart camera LSIS 422i reads dot-peened,
laser-etched and printed codes
05
Simply innovative–
MLD 500, MLD 300
14
PROFINET inside —
BCL 548i
World’s first barcode reader with
integrated PROFINET interface
07
In the third dimension
3D sensor system—high-tech reduced
to the basics
08
Sensor solutions
for your applications
Product highlights
10
Salt-resistant
Sensors in salt storage show off
their benefits
On track with trend-setting
sensors
Laser scanner ROD 4 unlocks new dimensions
for driverless transportation systems
Multiple Light Beam Safety Devices
with integrated muting
06
Safe in a few steps
15
Always well positioned!
Light-section sensors LPS in rails of a robot
application for door manufacturing
16
Moving bridges with
Leuze electronic
ODSL laser sensors measure distances
as the Oakland Bay Bridge is moved
within the scope of an extensive repair
18 中国欢迎您!
Interview with Mr. Matthias Höhl,
director of our subsidiary in China
Page 04
Fast reading of moving codes
Smart camera LSIS 422i reads dot-peened,
laser-etched and printed codes
With the device version LSIS 422i,
which can also read and verify
moving codes, Leuze electronic
offers users the option of code
reading via smart camera.
Motor-driven focus adjustment,
uniform illumination of free-form
surfaces, and connection technology suitable for industry characterize the smart cameras of the
LSIS 400i series. Equipped with
eight freely configurable I/O ports,
one RS232 interface and one Ethernet interface, the code readers can
conveniently be configured via a
web browser. A display for diagnostics and status display, as well as
standalone operation, round out the
advantages of the series.
The new LSIS 422i also offers all
these features. It can read up to
99 barcodes per image, whether
printed, laser-etched, or dotpeened, and 2D Data Matrix codes.
The fact that “only” one image
is captured also allows codes to
be read on quickly moving parts.
A prerequisite for this is a short
exposure time that can be set to a
minimum of 54 µs for the LSIS 400i.
Determining and evaluating
code quality
In addition to reading the codes,
quality parameters of the read
codes can optionally be determined
and evaluated. This means the code
quality can be checked immediately
after printing to ensure readability.
The user can specify the quality
criteria himself and, if necessary,
Adjustable parameters optimize
performance
One of the options for optimization
via software is the specification of
pre-filters with certain code
features in order to speed
up the reading process.
For 1D codes, you can
also increase the step
size of the search.
Other options
are read direction and inverted
codes.
Inverted twodimensional
codes can also
be read. With
these, the reading mode can
furthermore be
set: “fast” for
codes of good
quality or “robust” for
more critical, e.g. directly
marked, codes. If Data Matrix codes
are not presented as a square
shape but as a kind of hole pattern,
the algorithm recognizes these
codes as well. Even reflected codes
can be read by the software.
define a value below which a warning is output. In reference code
comparison, the reader also outputs
a message if the code read does
not conform to the specification.
Together with the configurable
data output, the new code reader
can be used just as flexibly as the
other Leuze barcode readers.
Page 05
Simply innovative — MLD 500, MLD 300
Multiple Light Beam Safety Devices
with integrated muting
Leuze electronic presents Multiple
Light Beam Safety Devices and, for
the first time, 3-beam transceiver
systems as well in various function
classes for access guarding, also
with muting. And no additional
modules are necessary!
It is advantageous from a cost
effectiveness and optimum usability standpoint to use safety
sensors that are characterized by
functions that match the specific
requirements of the given application as closely as possible.
Leuze electronic developed the
new MLD 300 (type 2, PLd) and
MLD 500 (type 4, PLe) series
Multiple Light Beam Safety Devices
especially with this in mind.
The individual models of the
respective series are equipped with
certain features and capabilities
(function classes). By selecting a
given function class, the
user can appropriately
determine the
performance of his safety
sensor for the application
and the respective requirements. For example, the
start/restart interlock and
contactor monitoring functions are available and, if necessary, various muting modes can be
selected. As a result,the series can
be used both as standard access
guarding as well as for applications
where sequential, parallel or partial
muting is required. Additional muting devices are not required, thus
simplifying construction and lowering costs during setup of the muting
application.
Higher MLD function classes,
such as MLD 330 or MLD 530,
feature an integrated muting indicator and a 7-segment display, which
the user can use to
immediately determine
the cause of sensor
behavior and initiate
the proper countermeasures.
The series
is predestined
for wide-area
perimeter guarding,
which is realized with Deflecting
Mirrors. Ranges of up to 70 m and
operating temperatures up to –30 °C
are here possible. With the integrated laser alignment aid, alignment of
such safeguards is noticeably simplified. A reflective element integrated in the cap on the receiver side of
the system ensures clear visibility of
the alignment laser spot, even over
long distances. The Deflecting Mirror columns necessary for perimeter
guarding can be simply and quickly
aligned, step-by-step. The setup
time is considerably reduced.
In addition, with the new BT-240
swivel mount, the safety sensor can
be flexibly turned 240° on its own
axis, easily aligned and reliably
mounted—an extremely practical
solution for further simplifying and
accelerating use of the devices.
We l l wo r t h s e e i n g!
MLD video clip at
www.leuze.com/mld-clip
Page 06
inside — BCL 548
548i
World’s first barcode reader with integrated
PROFINET interface
Thanks to the integrated interface, the barcode reader BCL 548i
can be operated directly in a
PROFINET network. Furthermore,
thanks to integrated switch technology, the BCL 548i can also be
used in a line network structure.
This minimizes cabling requirements and offers a high level of
transparency and flexibility.
Simple start-up and operation
The integrated PROFINET interface permits the BCL 548i to be
connected directly to a control.
The usual detour via an additional
gateway becomes unnecessary.
Moreover, with the integrated
PROFINET interface, the user can
easily operate the device via the
control. The device is configured
by selecting modules in the control
and then transferring them from the
control directly to the BCL 548i.
Should it be necessary to swap
out a device, the configuration is
automatically taken over by the new
device. By means of the integrated
switch function, additional devices
can be connected to one another
in the PROFINET in a line
structure, as is typical for
fieldbuses.
d
Worl t
firFsINET
PRO ide
ins
Fail-safe connection and
short mounting times
High system availability through
code reconstruction technology
The BCL 548i connects via standardized M12 plugs and ready-made
cables, making wiring economical,
transparent and fail-safe. The
well-designed fastening concept
contributes to easy handling and, in
particular, reduces mounting time.
The proven dovetail technology and
four M4×6 threaded holes make
possible simple and convenient
fastening in the system.
Alignment and configuration are
simplified by a well-structured and
transparent presentation of the values in a multi-language display. The
menu navigation is user friendly and
is performed using four buttons.
Two additional LEDs provide a quick
overview of the device status.
During operation, the superior performance of the BCL 548i ensures
high reading reliability. The innovative code reconstruction technology (CRT) guarantees this even in
fast processes. The advantages are
particularly apparent with turned
labels, with short label heights or
with codes that must be read at extreme inclines relative to the center
axis. Even partly damaged or soiled
codes can be decoded.
In addition to equipment and
technology, the new, future-oriented
barcode readers of the BCL 548i
series convince with a level of
performance that flexibly satisfies
every application-specific requirement, thereby saving time and
ensuring high system
availability, even under
difficult conditions
and increasingly
faster processes.
Flexibility through a wide range
of models
The wide range of barcode readers offers the user a high level of
flexibility for a variety of applications. The user can select from four
different optics models for various
module widths ranging from 0.25
to 1.0 mm. With identical reading fields, all are available as line
scanners, oscillating mirror models
or deflecting mirror models of the
latest generation. The high-performance optics, with a symmetrical, optical opening angle of ±30°,
permit wide opening of the reading
field with large depth of field, even
at close range.
Page 07
In the third dimension
3D sensor system—high-tech reduced to the basics
.
Ulrich Balbach,
Head of the
Optoelectronic
Sensors Division at
Leuze electronic
.
contact
What is a 3D sensor
system? What does it mean?
.
For optical sensors, we
have so far talked about measuring
or switching systems that determine
the distance or the presence of an
object by emitting a light beam.
These so-called one-beam systems
usually contain all distance information that is energetically or geometrically usable. In addition, there
are and have been surface-illuminated camera-based systems that
evaluate surface elements (called
pixels) two-dimensionally in the
plane with regard to their light/dark
distribution, usually at a higher
resolution.
If one combines the distance
information of the one-beam
systems and the high energy
deposit of their illumination with the
surface evaluation of a camera chip,
one can obtain additional depth
information—known as the third
dimension.
Along a laser line, one obtains not
only the location of each pixel in an
x/y-coordinate system and its
brightness value, but also the
distance via the z-coordinate.
Balbach
contact
Now what are the
benefits of 3D sensor systems?
.
The advantages are
obvious. The additional distance
information means that you depend
far less on brightness or color
differences on the object. A body’s
edge, for example, can safely be
distinguished from a light/dark
transition in the scene in this way.
This provides detection reliability. In
addition, the energy deposit is
higher by a factor of 1,000 for the
applied, structured illumination
when eye safety is taken into
account.
Balbach
.
contact
This sounds pretty
complicated. Doesn’t this result in
quite a lot of downstream effort?
.
No, just the opposite.
The processing of a 3D signal can
be considerably simpler. Body
edges, highest points and lowest
points, just to mention a few
examples, are contained directly in
the signal and can be extracted via
simple pair comparisons. Extensive
intermediate storage of the image
data for feature extraction is no
longer required. If the user wishes
to accept all data unfiltered in their
entirety from the sensor, he can use
a high-performance 100 MBit/s
(MBaud) Ethernet interface.
Balbach
.
contact
What are the areas of
application for such a 3D sensor?
.
For many applications,
simple point-shaped information is
more than insufficient nowadays.
For example, determining a pick
position for the robot’s grabber
requires a 3D coordinate in space.
Or, if one wants to determine the
volume of an object, this does of
course require the height in addition
to the length and width.
Balbach
.
contact
All of this sounds like
a lot of high-tech. Aren’t these
3D sensors very expensive?
.
Our developers at
Leuze electronic have landed a big
coup. They have taken this highly
challenging technology and, with a
few smart tricks, have reduced it to
the basics, so that the new light
section sensor family LPS can offer
the right product model at the right
price and performance for the
situation. The products range from
“simple” Line Range Sensors (LRS)
suitable for object detection to
models for measuring the position
and width, i.e., the Line Edge
Sensors (LES). For high-end
applications in 3D measurement,
various versions of Line Profile
Sensors (LPS and LPS plus) are
available.
Balbach
Page 08
Sensor solutions
for your applications
Miniature sensors
Series 2
Light section sensors
LRS (Line Range Sensors)
Three different operating principles—
from scanners to photoelectric sensors
Light section sensors for object detection
via scanning along a laser line
Particularly suited for installation in constrained spaces (23.1 × 8 × 12 mm)
Large detection range:
200 – 800 mm deep and up to 600 mm wide
The housing, fully molded with thermoelastic
elastomers (IP67), guarantees permanent protection and maximum operational reliability.
4 switching outputs
PinPoint LED for producing a small,
homogeneous and highly visible light spot
that is ideally suited for the detection
of small parts
Fast: 10 ms response time
Up to 16 detection fields with logic
combination
Easy integration through compact construction
Modular scanner portals
MSPi systems
Laser distance sensors
ROD 4-50plus
Application-specific optimized complete
systems for omnidirectional reading
Fastest laser distance sensor for area scanning
object measurement
Integration of up to 32 barcode
readers of models
BCL 500i and BCL 501i
Unbeatably fast through the use of
integrated Fast Ethernet 100 Mbit.
Code reconstruction technology (CRT):
Identification of soiled, turned (tilt angle) or damaged
codes
Measurement range 65 m
Omnidirectional reading
High scanning rate 800 – 1,200 scans/s (adjustable)
Scanning rate 50 Hz
Configuration during operation via online
commands
Integrated measurement data processing
Compact construction, low weight
Page 09
Sensor solutions
for your applications
Optical distance sensors
ODSL 9
Multiple Light Beam Safety Devices
MLD 500, MLD 300
High-end technology at standard prices for
width measurement or assembly monitoring
Transceiver systems for access guarding with
and without muting
Stable measurement values even under
difficult conditions, such as temperature
fluctuations and glossy surfaces
3 operating modes (fast—precision—standard) permit fast adaptation to applications
Resolution of up to 0.01 mm and measurement ranges of
50 – 450 mm are optimal for any task
Configuration directly at the device considerably simplifies
reading and configuring
3-beam transceiver replaces more complex
systems
Suitable for low temperature environments up
to –30 °C
Integrated muting functions for configuration
by means of pin assignments
Simple device exchange by means of Plug &
Play with no programming
Inductive switches
IS 288
Contrast scanners
KRT 20B
Compact design with lateral detection range
for space-saving integration
Mark detection, lid orientation, glossiness
distinction, small parts detection
Construction from Ø 6.5 mm to M30 and
NEW: 8 × 8 mm cubic
High-strength plastic housing with metal
threaded sockets
Stepped scanning ranges up to 40 mm provide the correct sensor for each application
Scanning range 13.5 mm
Switching frequencies of up to 5000 Hz offer
an extremely large dynamic range
Various teach-in processes
RGB or white light
Teach-in with EasyTune
IO-Link
Page 10
Salt-resistant
Sensors in salt storage show off
their benefits
Salinen Austria AG is Austria’s
largest producer of salt. The company has put a new high-bay warehouse into operation which, due
to the conditions present, is made
of a somewhat unusual building
material: wood. As the general
contractor, the Voralberg (Austria)
branch of LTW Intralogistics GmbH
supervised the project and used
sensors from Leuze electronic for
this extraordinary project.
With the expansion of production
capacity to more than one million
tons, it was necessary for Salinen
Austria AG to construct a new
high-bay warehouse at the production facility in Ebensee (Austria).
“In addition, the construction of an
automatic, single-level distribution
system reduces transport costs by
up to 40%,” explains the responsible logistics director of Salinen
Austria AG. The entire logistics
infrastructure was realized by
LTW Intralogistics: “As the general
contractor, LTW supplied multiple
complete systems, consisting of
high-bay storage devices, conveyor
systems, control technology and
software,” reports Ralf Becker from
the marketing department of LTW
Intralogistics in Wolfurt, home to
the Austrian headquarters of the
company.
Leuze electronic sensors
are essential
Sensor technology from Leuze electronic, such as the BPS 34 barcode
positioning systems, DDLS 200 data
transmission photoelectric sensors,
HRT 96 light scanners or ROBUST
Multiple Light Beam Safety Devices
used in Ebensee, have, for years,
played an important role in the performance of LTW projects. “They
provide us with the necessary process availability for fully automatic
operation,” confirms LTW, where, in
the context of the system constructed for Salinen Austria AG,
the largely corrosion-resistant
device versions are particularly
valued. These are also the reasons
for the wooden construction of
the warehouse at Salinen Austria:
the special challenge is the salt,
which would necessitate extensive
corrosion-protection measures on
the steel typically used to construct
high-bay warehouses. Wood was,
therefore, the better choice here.
Even without any special treatment, wood is largely resistant
to direct contact with salt and to
the high level of salt present in
the air in the warehouse (Figure 1).
Even metal screw connections
were eliminated, opting instead for
traditional carpentry dovetail joints.
Everything that could be made of
wood, was. This includes ladders,
provided for accessing the high-bay
storage devices for maintenance
work, or the stands for the control
panels. Many other system parts,
such as the high-bay storage devices, were hot-dip galvanized and
then coated in three layers. A total
of six high-bay storage devices with
a height of approximately 23 m, with
travel speeds of up to 4 m/s and lifting speeds of up to 1.5 m/s, ensure
a rapid flow of goods. Each of the
high-bay storage devices moves up
to 92 pallets per hour.
Figure 1: Wood is an unusual building material for
a high-bay warehouse. For the Salinen Austria
AG salt warehouse, however, it is ideal.
Figure 2: Absolute distances are encoded on
the plastic tape of the BPS 34. Shown here is
the tape affixed to the vertical axis of a high-bay
storage device.
Page 11
Precise positioning
with barcodes
The positioning of the
high-bay storage devices
in the high-bay warehouse
and of the side-tracking
skates in the pre-zone occurs with BPS 34 barcode
positioning systems, each
of which consists of two
easy-to-handle components: a read head and the
barcode tape. With a high
level of functional reliability
and minimal maintenance,
the BPS from Leuze electronic are predestined for
use in such demanding
applications. The plastic
code tape, on which the
absolute distances are
encoded, is a key contributing factor here (Figure 2).
The code is nearly indestructible and insensitive to
UV light and many industrial environmental influences, such as various oils
and chemicals, humidity, etc. For
simple mounting, the tape, produced by Leuze’s Austrian partner,
Schmachtl GmbH of Linz, is self-adhesive and affixed to V4A stainless
steel. It can easily be attached to
the floor with plastic holders.
With the reader system, a laser
scans the position information with
a reproducibility of ±1 millimeter.
The positioning system transmits
the respective, calculated position
value to the control every 2 milliseconds. One unique feature here
is that the read head always reads
multiple codes on the code tape
simultaneously (Figure 3). Thus,
individual soiled or damaged codes
do not affect the measurement system, which operates using absolute
values, thereby ensuring reliable
position detection.
Optical data transmission
without interference
All data is exchanged between
the high-bay storage devices, the
side-tracking skates and the control
via data transmission photoelectric
sensors DDLS 200. They permit
contact- and wear-free optical communication without interference at a
transmission rate of up to 2 Mbit/s
over distances of up to 500 meters
(Figure 4).
The device versions used here
are designed for aisle lengths of up
to 120 meters. Each consists of a
pair of two transmitter and receiver
units, which transmit and receive
the data on different frequencies
via a pulsed, invisible, infrared laser
beam. Here, the laser beam of the
transmitter is precisely tuned to the
frequency of the opposing receiver.
This enables bidirectional communication and prevents mutual interference or reflections.
In addition to the device performance, LTW Intralogistics is
particularly pleased with the simple
commissioning. The patented SHA
(Single Hand Adjustment) process
for one-man adjustment allows a
single person to precisely align the
data light beam.
Salinen Austria AG also uses
other products from Leuze electronic in the area of space occupancy detection within the scope of
double-deep storage in the highbay warehouse. For example,
reflection light scanners with
background suppression of the
96 series are used. The laser light
scanners have a large detection
range. They operate according to
the principle of light propagation
time measurement and facilitate use
under extreme conditions with
respect to light and gloss. Furthermore, they offer good black/white
behavior over the entire adjustment
range and a switching behavior that
is independent of the direction of
movement.
Figure 3: The read head of the BPS 34 always reads
multiple codes on the code tape simultaneously
(source: LTW Intralogistics GmbH)
Figure 4: DDLS 200 data transmission photoelectric
sensors on high-bay storage devices facilitate contactand wear-free optical communication.
Page 12
Safe in a few steps
Premounted Safety Sensor Sets simplify
the setup of access guarding
it is often necessary for
the material that is being
processed to be able to
pass through the protective device without
restricting productivity.
For this purpose, robust
protective devices that
include the so-called
muting function and that
can be easily integrated in
the safety system of the
system are required.
- Freedom from interference—
the system does not need to be
adapted to the safety technology
This was easily solved with CPSET
from Leuze electronic, based in
the Swabian town of Owen/Teck
(Figure 2). CPSET are customized
complete systems consisting of
optical protective devices for access safeguarding and feature an
integrated muting function.
CPS E T-M24
Components increase
complexity
Figure 1: Systems for transport and handling in the
wood industry.
Machine manufacturers wishing to
implement access guarding with
muting are often confronted with
the problem that numerous
individual components need to be
ordered, installed and matched to
one another. This can be performed faster and easier with
premounted and preconfigured
Safety Sensor Sets, such as the
CPSET from Leuze electronic. J. B.
Maschinen- und Anlagenbau
GmbH has been able to experience
this, too.
J. B. Maschinen- und Anlagenbau,
based in the northern German town
of Lamstedt, has produced machines and systems for transport
and handling in the wood industry
since 1997 (Figure 1). Because
these highly efficient systems contain various hazard locations, they
must be appropriately safeguarded
in accordance with the European
machinery directive. In this regard,
Up to now, this was accomplished by ordering
various components—in some cases, even from different suppliers—
and then, with great effort, connecting them to create a safety system.
This considerable effort associated
with the installation, alignment and
integration of the safety technology into the switch-off circuit of
the machines was impetus for J. B.
Maschinen- und Anlagenbau GmbH
to shop around for a complete system for the safeguarding of access
points with material infeed. General
Manager Mr. von Holten said in this
regard: “We need economical, easyto-mount and reliable complete
systems.” The requirements on such
a system included, among others:
- Complete system with integrated
muting control
- Simple integration in the safety
circuit of the machines and systems
- High availability, even in noisy
environments
The core element
of CPSET is a
COMPACTplus muting transceiver or a
Multiple Light Beam
Safety Device of
type 4 acc. to
IEC/EN 61496-1
or SIL 3 acc. to
IEC 61508. The
CPSET-M24 Safety
Sensor Set includes the muting
transceiver and is
used for 2-beam
access guarding with 4-sensor
sequential muting.
The set is preconfigured. Nevertheless, adaptation by
means of switches
in the sensor or via
the SafetyLab PC
software are generally possible.
Page 13
One order—everything is
delivered ready for use
The CPSET-M24 used by J. B.
Maschinen- und Anlagenbau
includes, in addition to the
COMPACTplus muting transceiver,
the device columns, Deflecting
Mirrors, muting sensors, mounting
brackets, connection cables and the
display and control unit (Figures 3
and 4). This operating box has a
Figure 2: CPSET in a handling system
for the wood industry.
reset button for the start/restart
interlock and for overriding following a muting fault (muting restart/
override). It also includes a LED
indicator and is prepared for direct
mounting on the hard guard. The
set, with all necessary components,
can be ordered by specifying just a
single CPSET part no.—instead of
many individual items. This simplifies the ordering process immensely. Everything needed arrives on the
same day—premounted
and ready for use.
The customer-specific presetting of the
“intelligent” muting transceiver, i.e. configurable for
various application cases,
effectively prevents false
alarms caused by interference, such as wood
shavings or gaps in the
muting object. With its
secure relay output, the system can
easily—and with no additional costs
for safety relays—be integrated in
the switch-off circuit of the machine.
At J. B. Maschinen- und Anlagenbau, CPSET-M24 ensures that
access safeguarding can be put into
service quickly out-of-the-box and
that a safe system with high
availability is delivered to the end
customer. The good cooperation
with the Leuze electronic field staff
has resulted in the CPSET-M24
being adapted to meet the specific
requirements of the customer. The
system is now used both quickly
and trouble-free as standard access
guarding by J. B. Maschinen- und
Anlagenbau. Mr. von Holten
summarized this as follows: “With
the CPSET series, Leuze electronic
has brought an economical solution
to the market for the customer.”
Figure 3: Detailed view of the UDC device column
with muting transceiver (in the column) and
mounted MMS Muting Mounting System, including prewired muting sensors.
Figure 4: CPSET-M24 with display
and control unit (right).
Page 14
On track with trend-setting sensors
Laser scanner ROD 4 unlocks new dimensions
for driverless transportation systems
Driverless transportation systems
(FTS) perform transport tasks
economically and fully automated.
With the innovative ROD 4 laser
scanner from Leuze electronic,
SIEMENS guides such systems by
means of 3D laser navigation on
the hall ceiling, thereby reaching a
new dimension: both navigationally
and economically (Figure 1).
The cost effectiveness of driverless
transportation systems (DTS) stems
primarily from the automatically
operated transport vehicles, i.e.
with no human operator. However,
depending on the navigation system
that is used, structural measures
requiring high planning effort are
usually necessary in the surrounding environment. These may be carriages, induction loops or magnets
in the floor, or laser scanners that
normally scan over an area, i.e. two
dimensionally, and require reflectors
on walls, shelves, machines etc.
The possible flexibility with respect
to changes of
Figure 1: With innovative
transport tasks
3D laser navigation on the hall
is more or less
ceiling, SIEMENS driverless
limited.
corridor supply vehicles operate
Furthermore,
reliably and safely.
production-related
or structural
changes in the
surroundings,
such as modified
machines and
systems or
relocated shelves,
interfere with the
transport process.
The laser scanner
ROD 4 by Leuze
electronic in the
new Autonomous
Navigation
System ANS by SIEMENS (Siemens
Division Industry Automation and
Drive Technologies) unlocks new
dimensions for driverless corridor
supply vehicles. This applies both
to the spatial plane used for
navigation, namely the hall ceiling,
as well as to the cost effectiveness,
achieved through lower installation
costs, as no navigation aids need to
be installed on the floor, walls or
system parts. Last, but not least,
ANS also facilitates maximum
flexibility for route changes in
today’s rapidly changing production
environments.
Figure 2: ROD 4 laser scanners from Leuze electronic,
with their laser distance measurement technology
for 3D contour measurement, serve as the basis for
the innovative Autonomous Navigation System (ANS)
from SIEMENS.
Spatial representation of the
hall ceiling
For the navigation of driverless
transportation systems, the ROD 4
laser scanner is mounted on a swivel motor on the top of the vehicle
(Figure 2). The fast, pulse propagation time technology of the ROD 4
enables the detection of 3D profiles
that can be generated by means
of swiveling and a linear forward
motion of the vehicle relative to
one another. This creates spatial
representations of the surrounding
environment - in this case the hall
ceiling - which then serve as the
basis for free navigation. “The new
3D laser navigation system can be
installed on a wide range of different types of indoor vehicles, from
high-lift trucks to industrial trucks,”
explains engineer Walter Beichl,
the project manager responsible
for ANS at Siemens. “We are able
to attain a navigation quality that is
sufficient for most logistics requirements,” Beichl adds.
Absolute operational reliability
included
Compared to conventional DTS
installations, the installation effort
associated with the Autonomous
Navigation System with the ROD 4
laser scanner is much lower. This
system requires absolutely no structural measures and can be quickly
commissioned, because the route is
defined by means of 3D laser
navigation on structural contours
present in the vicinity of the hall
ceiling. Even subsequent route
changes can be integrated at short
notice and in just a few minutes.
Even the integration of individual
vehicles into existing productionand logistics processes is an
economical possibility, independent
of the current production layout.
Flexibility in a future-proof logistics
plan is, thus, no longer bound by
any limits.
Page 15
Always well positioned!
Light-section sensors LPS in rails of a robot application
for door manufacturing
To be also able to determine
3D gripping positions even for
large-sized objects, Leuze electronic has deliberately designed its
LPS series light-section sensors
for a large measurement range
of 200 to 800 mm. The compact
construction of the sensor permits its integration directly into
the grabber, which makes the LPS
series the ideal solution for robot
applications for special-purpose
machine manufacturer G. Kraft
Maschinenbau.
Often, the stacked doors are not
all of the same model, and may not
lie exactly on top of each other.
The stack also decreases in height
each time a door is grabbed. This
means that the robot needs an intelligent position detection system for
grabbing, such as an LPS made by
Leuze electronic. “The robot see
within a short distance and must
position itself within just a few millimeters. The LPS light-section sensor is exactly the right product for
this purpose” says Berthold Sudahl,
head of the robotics department at
G. Kraft Maschinenbau.
Line profile sensors (LPS)
measure the dimensions or the
due to a lack of alternatives. These
sensors are used wherever products are on a pallet or have a large
variation in position. In addition
to its 160 × 74 × 56 mm compact
construction, the LPS 36 is characterized by a response time of 10 ms,
a 600 mm laser line at 800 mm
distance and an Ethernet interface.
With a 100 Hz measurement rate,
the sensor achieves a resolution
between 1 and 3 mm; its transmitter and receiver are accommodated
in a single unit and are already
adjusted.
The sensor has many advantages
for G. Kraft Maschinenbau: It has no
moving parts and permits easy
G. Kraft Maschinenbau GmbH
is based in Rietberg-Mastholte,
Westphalia. It manufactures specialpurpose machines for the wood
processing industry
and the production
of radiators, wooden
flooring, sandwich
panels, packaging,
doors and frames.
For the embedding
of fittings into doors
with the CNC fitting
embedder TCF 70,
the unmachined doors
are manually stacked
on a roller conveyor.
An offset in position
of ±100 mm and a
Figure 2: The LPS light-section sensors
twist angle of ±10° is
from Leuze electronic are characterized
permitted in this procby their compact construction.
ess. A robot scans the
geometry of the door
Figure 1: Robot feed system with automatic tool changer and vacuum
stack using a special
installation on the
suction rail with integrated light-section sensor LPS 36.
module rail by G. Kraft
robot’s grabber
Maschinenbau with
(Figure 2). The door
an integrated sensor. From this
position of static or moving obmanufacturer also appreciates the
data, the twist angle and the door
jects. At a measurement range of
option to switch off the visible laser
center are computed. This lets the
200 to 800 mm, these light section
line, the integrated alignment aid in
robot grab the doors at the correct
sensors cover a large area of apthe display, and the single-shot
position and deposit them into the
plications that previously required
operation that considerably reduces
TCF 70 (Figure 1).
over-dimensioned sensor solutions
the data volume.
Page 16
Moving bridges with Leuze electronic
ODSL laser sensors measure distances as the Oakland Bay Bridge
is moved within the scope of an extensive repair
Leuze electronic BV of Waardenburg (Netherlands) and Syrinx
Industrial Electronics, also of the
Netherlands, play an important
role in the construction of the
Bay Bridge in San Francisco in the
U.S. state of California.
The Oakland Bay Bridge connects
Oakland and San Francisco. Every
day, 300,000 vehicles travel over
this important, five-lane, doubledeck toll bridge. Following the severe earthquake in San Francisco in
1989, it was decided to replace part
of the link between Oakland and
San Francisco with a new bridge.
To realize this connection, it was
necessary to temporarily move part
of the old, existing bridge (expected
to be completed by 2013) in order
to make space for the construction
of the new bridge.
The final construction step in
the realization of this detour was
the separation of a 100 m long,
3200-ton section and the subsequent moving of this section of the
bridge. Afterward,
a new, 3600-ton
bridge section
was pushed into
the resulting gap
to complete the
detour section—all
at a height of 50 m.
This work was performed on Labor
Day weekend in
2009 and had to be
completed within
three days.
In the spring
of 2009, Syrinx
Industrial Electronics was contracted
by Mammoet, the well-known Dutch
specialist for transport and assembly solutions in the heavy-load sector, to develop a central monitoring
system for this project. The system
was to allow all movements to be
displayed on a large, 42-inch screen
as the bridge parts were moved.
time. Affixed to a mounting plate,
the Leuze electronic sensors could
be easily applied and positioned
through the use of strong magnets
(Figure 1).
Measurement of both small
and large distances while moving
the bridge
During the move, the bridge was
pushed upward at four points approximately 30 cm and then moved
laterally by means of hydraulic
winches with a stroke of 1.5 m
(Figure 2). The height and position
of the various hydraulic winches
were converted to 4 to 20 mA measurement signals with the aid of the
Decision for laser distance sensors
from Leuze electronic
A total of 31 laser distance sensors and 16 pressure sensors were
used. For the monitoring of this
challenging project, Syrinx Industrial Electronics chose ODSL laser
distance sensors from Leuze
electronic. Decisive here was their
precision, robust design and the
display, which allows measurement
values to be read on the spot. As
a result, it was not necessary to
constantly run back to the central
laptop to make adjustments during
installation. Considering the large
distances, this saved considerable
Figure 1: The mounting plate with the sensor is
attached and aligned by means of a magnet
(source: Syrinx Industrial Electronics, www.syrinx.nl)
Page 17
Leuze electronic ODSL 96B laser
distance sensors.
The horizontal movement was
over a distance of approx. 30 m
and was measured with Leuze
ODSL 30 laser distance sensors.
This model was chosen on account of its RS485 output. Syrinx
Industrial Electronics constructed
a converter box for this output to
convert the RS485 information to an
exact, 16-bit analog signal of 4 to
20 mA. In this way, it was possible
to attain even greater precision over
the entire measurement range up to
50 m.
In addition to the converter
boxes, Syrinx Industrial Electronics
also developed eight measurement
boxes to which all laser sensors and
the used pressure
sensors could be
connected (Figure 3).
Together, all of the
measurement boxes
formed the complete
measurement network
that was connected to
the laptop. The laptop
was then connected
to the 42-inch
monitor, on which the
processes could be
Figure 2: The distances during the bridge movement are
visualized, as Syrinx
measured by the ODSL 96B (source: Syrinx Industrial
Industrial Electronics
Electronics, www.syrinx.nl)
also programmed a
solution for the
complete visualization
for this project
(Figure 4).
Figure 3: Interface to the laptop: the measurement box,
to which all sensors can be connected
(source: Syrinx Industrial Electronics, www.syrinx.nl)
Inf o rm a t i o n o n
Syrinx Industrial Electronics
realizes numerous projects for
many different clients. Projects
involve the development and
production of customer-specific
hardware and software. All
necessary steps, even series
production, take place inhouse. Syrinx Industrial Electronics specializes in the area of
industrial weighing technology
and interfaces. The company
was present onsite during the
entire Bay Bridge project and
constructed the measurement
system together with its client
Mammoet on location. This is
only one of many projects that
the Dutch engineering firm has
realized in cooperation with
Mammoet. The next projects
are already in the planning
stage. Here, too, Syrinx Industrial Electronics will again use
Leuze electronic sensors.
www.syrinx.nl
www.mammoet.com
Figure 4: Syrinx Industrial Electronics handled all visualization
(source: Syrinx Industrial Electronics, www.syrinx.nl)
Page 18
中国欢迎您!
Matthias Höhl is the director of our subsidiary in China, which he
founded back in 2005. After operating for 5 years in a rapidly growing
country, it is time to report on some interesting developments of the
company, the country and its people. China has changed extensively,
and who would be in a better position to talk about it than someone
who has lived in China for the past 10 years?
.
contact
Good day, Mr. Höhl.
To start, could you please briefly
introduce yourself to our readers and tell us how you came to
Leuze electronic in China?
.
It’s a pleasure. 40 years
ago, I was born near Frankfurt.
After an apprenticeship as a communications technician, I studied
Electrical Engineering and started
my career as product manager in a
mechanical engineering company.
I got to know international business
early on through numerous travels,
leading me to Asia in particular.
Since 2000/2001, I live here in
China, with intermediate stations
in Hong Kong and Taiwan. My wife
was born in Taiwan and my son in
Hong Kong, I think you can well
and truly call this an international
family! In 2005, I founded a new
company for Leuze electronic in
China. Having gained experience in
mechanical engineering, the transition to automation products wasn’t
that hard.
Höhl
.
contact
How has Leuze electronic developed in China until
now?
.
Leuze electronic started in
2003 with a representative’s office.
After establishing our wholly-owned
Höhl
subsidiary Leuze electronic Trading
(Shenzhen) CO., LTD in September
2006, we progressed to a team
of 15 staff in Shenzhen, Shanghai and Beijing. Today, there are
over 40 “sensor people” in China.
I would like to mention in particular
our aim to provide the same technical competency in China as we do
in Europe. Professional consulting
and finding individual solutions
for the customer are always top
priority.
.
contact
You assemble locally
for the Chinese market?
.
Yes, the first photoelectric
sensors and scanners of the 318
Series were assembled in China in
May 2007. Starting with the simpler
models, we now manufacture the
entire range. I am
very proud that we
have not just managed to maintain
the original quality,
but that we were
even able to improve on it. This
requires detailed
goal setting,
of course,
maintaining
specifications
and continu-
Höhl
G re a t W
a ll o f C
hin a
ous monitoring of the quality. This
applies in particular to purchasing
parts and materials. As in Germany,
we concentrate on the final assembly and function test of the
sensors.
.
contact
What role does ‘Made
in Germany’ still play in China?
.
In China, “Made in
Germany” is still number 1. German
companies can take advantage of
this view and improve their
positioning against products from
other countries. It still applies:
Products from Germany are of high
quality and robust, but unfortunately also expensive. I would like to
see the Chinese appreciate the
quality more and hope that this
will improve over the coming
years.
Höhl
Fo rb id de n
Traditional Chinese clothing
Page 19
IN SIDER TIP
Shenzhen
.
contact
On which industries do
you focus your attention and how
will they develop in the next few
years?
.
The packaging technology,
intralogistics, and the automotive
industry show enormous growth
potential in China. We hope for the
biggest growth rate in packaging
technology as the shopping habits
of the Chinese change increasingly.
In the past, food was grown in the
backyard or bought daily on the
market. Today, the supermarket
is the norm. Firstly, this leads to
an immense increase in packaging, and secondly products need
to be stored and the flow of goods
must be managed logistically. This
requires distribution centers with
high-bay warehouses, leading us to
our second industry, the intralogistics.
Chinese salaries increase continuously. 10 years ago, the focus
was on owning a flat, today it is
on owning a flat and a car. This
development is extremely rapid
and since last year, China is
the largest car manufacturer in the world. In the
city of Shenzhen alone,
1,000 new cars are
registered each day, with
an increasing trend. So
Höhl
far, however, only 10 – 15% of the
population live in the metropolitan
and industrial areas and can afford
this “luxury”—we now have over
one thousand billionaires in China!
The local market is just beginning
the journey, certainly the saturation
will occur only in a few years.
.
contact
What are the particular
challenges in the Chinese market?
.
China is a large country—
and every day, this is the biggest challenge for our team. The
promotion of the provinces in the
hinterland and the low salaries
that still prevail there increasingly
attracts industry there. The biggest
challenge is to follow and serve the
market, which requires the right
number of sales representatives
and good regional business associates/distributors.
The start of each discussion is
about technical solutions, but also
about the price. Our trained staff
always offer the customer the
ideal solution under both price and
technology aspects. The need to
deliver products with higher quality
increases the demand for hightechnology products in China. In
combination with products adapted
to the local market, this leads to a
very good situation for us in
the near future.
Höhl
.
contact
Are there
particular things one
should take into account when traveling
to China?
.
China has
changed. The particular features that
Höhl
Ci ty in Be ijing
Sk ylin
ng
e of Ho ng Ko
Shenzhen used to be a small fishing town
known as “The kingdom of the last Chinese
leader Deng Xiaoping.” Founded in 1979 for
experimenting and playing with capitalism
using the parameters of Chinese socialism, the
total area today is 1,948 square kilometers with
a registered population of about 12 million.
The summer is exceptionally long (about six
months) and warm (up to 38°C). The temperatures during winter rarely fall below 10°C. With
a blue sky and 25°C, the months of November
and December are best for visiting Shenzhen.
Accommodating 56 different Chinese ethnic
groups, the city offers a wide range of food and
drinks.
My top location for relaxing with exceptional
local food:
Laurel Restaurant: 1F. Portofino Club House •
Overseas Chinese Town • OCT, GD China
‘I hope I could give you a small insight into Shenzhen—China is just too large for a few words.’
you might know from presentations can often only still be found
far away from the big cities. On the
one hand, this is a pity since China
abandons a part of its culture. On
the other hand, awareness about
the environment increases. The
younger generation in particular
has changed many customs and
traditions. Spitting and eating dogs
is no longer practiced. Nowadays,
many Chinese walk their dog or cat
on a Sunday. For journeys into the
hinterland, I recommend local or
professional guides.
Welcome to China!
INTERNATIONAL REPRESENTATIVES
15 distribution companies
42 distributors
AUSTRALIA
DENMARK
NETHERLANDS
SWITZERLAND
Balluff-Leuze Ltd
Leuze electronic Scandinavia ApS
Leuze electronic B.V.
Leuze electronic AG
12 Burton Court, Bayswater
Gydevang 33
Ringweistraat 6
Rothusstraße 5b
VIC 3153
3450 Alleroed
4181CM Waardenburg
6331 Hünenberg
Phone +61 3 9720 4100
Phone +45 48173200
Phone +31 4 18 65 35 44
Phone +41 44 834 0204
Fax +61 3 9738 2677
[email protected]
Fax +31 4 18 65 38 08
Fax +41 44 833 2626
[email protected]
www.leuze.dk
[email protected]
[email protected]
www.leuze.nl
www.leuze.ch
www.leuze.com.au
FRANCE
BELGIUM
Leuze electronic Sarl.
SOUTH KOREA
TURKEY
Leuze electronic nv/sa
Z.I. Nord de Torcy, B.P. 62-BAT 3
Leuze electronic Co., Ltd.
Leuze electronic San.ve Tic.Ltd.Sti.
Steenweg Buda 50
77202 Marne la Vallée Cedex 1
405 Anyang Geonseol Tower
Barajyolu caddesi, Burak Sokak,
1830 Machelen
Phone +33 1 6005 1220
Bisan-dong 1112-1, Dongan-gu
Darende is Merkezi, Kat:4 Daire 9,
Phone +32 2 253 1600
Fax +33 1 6005 0365
Anyang-si Gyeonggi-do
Atas¸ ehir
Fax +32 2 253 1536
[email protected]
Korea P.O. 431-050
34779 Ümraniye-Istanbul
[email protected]
www.leuze-electronic.fr
Phone +82 31 3 82 82 28
Phone +90 216 456 6704
Fax +82 31 3 82 85 22
Fax +90 216 456 3650
GREAT BRITAIN
[email protected]
[email protected]
BRAZIL
Leuze electronic Ltd.
www.leuze.co.kr
www.leuze.com.tr
Leuze electronic Ltda.
Sensor House
Av. Leonardo da Vinci, 1190
Phoenix Business Park
SPAIN
USA
Vila Guarani
Eaton Socon
Leuze electronic S.A.
Leuze electronic, Inc.
04313-001 São Paulo – SP
Cambridgeshire, PE19 8EP
c/o Juan Güell, 32 bajos
55395 Lyon Industrial Drive
Phone +55 11 5180-6130
Phone +44 14 80 408 500
08028 Barcelona
New Hudson, MI 48165
Fax +55 11 5181-6141
Fax +44 14 80 403 808
Phone +34 93 409 7900
Phone +1 248 486 4466
[email protected]
[email protected]
Fax +34 93 4 90 35 15
Fax +1 248 486 6699
www.leuze.com.br
www.leuze.co.uk
[email protected]
[email protected]
www.leuze.net
www.leuzeusa.com
www.leuze.be
CHINA
ITALY
Leuze electronic Trading
Leuze electronic S.r.l.
SWEDEN
(Shenzhen) Co. Ltd., Headquarters,
Via Soperga 54
Leuze electronic Scandinavia ApS
Xihaimingzhu Room 501-510
20127 Milano
Industrigatan 44B
Plaza, No.1 Taoyuan Rd.,
Phone +39 02 26110643
571 38 Nässjö
Nanshan District Shenzhen
Fax +39 02 26110640
Phone +46 380-490951
Postcode: 518059
[email protected]
[email protected]
Phone +86 755 862 64909
www.leuze.com/it
www.leuze.se
Fax +86 755 862 64901
[email protected]
www.leuze.com.cn
Issuer
Editors
Leuze electronic GmbH + Co. KG
Marketing and Communication
Postfach 11 11
D-73277 Owen / Germany
Phone
+49-7021-573 - 0
Fax
+49-7021-573 - 199
[email protected]
www.leuze.com
Volker Aschenbrenner
(responsible editor),
Thomas Röhrle
Matthias May