THE SENSOR PEOPLE · to our booth at SPS in Nuremberg. Kind regards, Ulrich Balbach Managing Director 2. COVER STORY LIKE IN A ... The new RSL 400 Page 10 FOUR POINTS SHOW US THE

“LIKE IN A ROLLER COASTER”The special application with the BPS bar code positioning system

Edition 1.14 | The Technical and Customer Magazine

THE SENSOR PEOPLEmagazine

Editorial

Dear Reader,

You have certainly already noticed the new layout and title of our customer magazine. Quite a bit has happened at Leuze electronic since the last issue. Under the motto “smart sensor business,” we have put into words what characterizes us as sensor people.

On the one hand, we place clear focus on optimum usability of the devices even during development. On the other is our concentration on applications and industry sectors in which we are able to offer extensive practical know-how and a comprehensive product portfolio. And – last but defi nitely not least – service offers that were developed at the request and to meet the needs of our customers and which are constantly refi ned further.

In our product presentations and application reports in this issue, you are certain to quickly notice this new approach.

In addition, we celebrated 50 years of Leuze elec-tronic in the past year. On the occasion of this anniversary, we opened our new sensor techno-logy center in Owen and the expanded production area in our Chinese plant in Shenzhen. On the one side, this is a clear commitment for us to our location in Germany as the nucleus of our success. On the other side, it is also an investment in the international orientation of our company.

You can fi nd further information on this topic in this magazine as well as reports on product innovations from various segments. There is, for example, our new RSL 400 safety laser scanner which, with an innovative fastening concept and two autonomous protective functions, offers unique possibilities that are currently unmatched anywhere in the world. Or the completely newly developed DDLS 500 optical data transceiver which, in addition to 100 Mbit/s real-time data transmission, scores with a conve-nient laser alignment aid and a mounting solution that is as simple as it is clever.

Reports on the practical use of our products at renowned customers, such as AUDI AG in Ingolstadt, where the LSIS 400i smart camera is reliably at work in automated door installation in vehicle body construction, are sure to make the articles interesting for every reader.

I hope you enjoy reading our new “sensor people magazine” and would be pleased to welcome you to our booth at SPS in Nuremberg.

Kind regards,

Ulrich BalbachManaging Director

Kind regards,

Ulrich Balbach

2

COVER STORYLIKE IN A ROLLER COASTER

The special application with the BPS bar code positioning system Page 8

50 YEARS OF SUCCESSCommitment to location and to globalization Page 4

LABELING PERFECTIONForked sensors and bar code readers support reliability in weigh-price labelers Page 26

SAFER DANCE FLOOR! Optical safeguarding of the workspaces at pipe-bending machines Page 12

DESIGNED FOR PERFECTIONLSIS 400i smart cameras in the automated door assembly in vehicle body construction at Audi Page 20

“ONE SENSOR – TWO PROTECTIVE FUNCTIONS – ENORMOUS SCANNING RANGE!”The new RSL 400 Page 10

FOUR POINTS SHOW US THE WAY!The new DDLS 500 Page 14

AND NOW YOU CAN BENEFIT!Only from us: “smarter product usability” Page 16

ALWAYS KNOW WHERE YOU AREThe new BPS 300i Page 18

THIS LIGHT-BAND CAN DETECT EVERYTHING – ROUND, ANGULAR, GLOSSY, WITH GAPS The new RK 46C VarOS Page 24

WE’VE SIMPLY DONE AWAY WITH ALIGNMENT!The new PRK 18B Page 28

TOP PRIORITY: NO INJURIES!Crash simulation system at Continental Page 30

3

50 YEARS OF SUCCESSLeuze electronic celebrated its anniversary and, with the new sensor technology center, strategically positions itself for the next 50 years.

4

5

COMMITMENT TO LOCATION AND TO GLOBALIZATION

Investment in innovation is the motto of the “sensor people”, for guaranteeing competitive capability from Leuze electronic in the future as well. In addition to opening a plant in China with state-of-the-art production technology, the company inaugurated a sensor technol-ogy center at its headquarters in Owen. What objectives is Leuze electronic pursuing with these multi-million euro investments and what value do they provide to the customers?

2013 was an event-fi lled year: Leuze electronic opens new sensor technology center at headquarters in Owen. The festive inauguration of the new facility took place during the anniver-sary celebration in July, at which some 1,600 visitors celebrat-ed the 50th anniversary of the company’s founding. This was a noteworthy event, particularly if we take brief look back at the start.

Then.

On January 1, 1963, Leuze electronic was founded as part of R. & M. Leuze OHG. Commercial administration and manage-ment fell on Christof Leuze who had been heading the discon-tinued weaving mill. With two knowledgeable companions and four employees from the textile industry, he began work in the “photoelectric sensor industry” in a small section of the former Leuze textil weaving mill in Owen. This marked the birth of Leuze electronic.

And today?

The signs point towards growth. Over the years, numerous facilities were added at various locations around the world. In the most recent expansion phase, the new sensor technology center – a three-story offi ce building with about 2,000 square meters of fl oor space and a hall of the same size for state-of-the-art production facilities with associated areas for produc-tion planning and control – was erected on the company grounds in Owen last year.

Ulrich Balbach, Managing Director of the company, explains the underlying strategy: “An investment such as this lays the foundation to allow Leuze electronic to further expand its position on the global market and to continue production and sales of its automation technology on a world-class level in the future as well.”

The sensor technology center is simultaneously a pledge to the Owen location, where a staff of 400 is employed. With about 900 employees and 17 subsidiaries, Leuze electronic is today present around the world.

Applied process optimization.

The new sensor technology center has resulted in an optimum consolidation of the individual departments. For employees, this means many other advantages in addition to shorter distances. The areas of production, order center, logistics, in-dustrial engineering as well as all production locations world-wide have now been grouped together under a single manager, a position fi lled by Michael Blank as “Director of Global Opera-tions.” He puts the advantages of the synergy effects in a nutshell: “Profi ting from the fast processes above all are our customers, because the permanent ability to deliver is an abso-lute must for many of them. Through refi ned logistics, custom working systems, short distances and highly fl exible employ-ees, we can react more quickly – even when requests are received on short notice.”

Optimized ergonomics and short distances are the key features of the new

sensor technology center.

6

High tech in the middle of

the breathtaking nature of

the Swabian Alb.

Global success.

Leuze electronic now generates more than half of its revenue abroad. On the topic of international growth, Ulrich Balbach says: “We are well equipped as a globally active company, not only in Owen, but around the world. In addition to our well-es-tablished locations in Fuerstenfeldbruck and Unterstadion, we are also present in our key markets in the USA, Brazil and China with our own production facilities.”

In fact, Leuze electronic invested several million euros in sys-tems and operating equipment in the Chinese city of Shenzhen last year. On this topic, Ulrich Balbach says: “In 2013 we prepared both in China and in Owen for further growth – the reason why we opened our new plant in Shenzhen.”

In Asia for Asia!

Matthias Höhl, responsible managing director for Asia, explains the most important advantages for the customers: “With this investment, Leuze electronic has an effi cient logistics chain on

the Chinese market and can offer local customers very short reaction times, optimum service and warranty coverage on-site as well as cost advantages.” Leuze electronic assembly (Shenzhen) CO., LTD. is now offering safety products and optical sensors for the Chinese distribution company Leuze electronic Trading (Shenzhen) CO., LTD. on 2,500 square meters of fl oor space for production, storage and offi ces.

The overall result.

Matthias Höhl sums up: “When we started in China in 2006 with 14 employees, our goal was to be among the fi ve most well-known sensor manufacturers in China within eight years. In China we today have the largest sales and subsidiary of Leuze electronic world-wide. I can today proudly say: we have accomplished much more than we had hoped at the onset.”

In China we can clearly see what applies for the entire company: targeted investments with the right strategic decisions lead to above average growth. Leuze electronic is well prepared for the future.

A SHORT LOOK AHEADMr. Balbach, what is particularly important for the future?“A large investment in technology leads to the need to multiply this investment. This is only possible by intensively linking sales activities and market observations with corresponding product strategies. But to ultimately be successful, customer proximity and high fl exibility are also essential.”

How does Leuze electronic respond to the requirements of tomorrow?“By preparing ourselves in the operational areas equally for mass production as well as for exacting, single-item production, we can respond to the fl uctuations of highly volatile markets. In doing so, we satisfy the high demands of our customers with respect to availability, application suitability and ease of use with our ‘smart sensor business’ philosophy.”

7

AIBA stands for “Automated Indoor Braking Analyzer”, i.e. automatic, weather-independent braking analysis, and is the world’s fi rst test track of its type. With AIBA, Continental makes great progress in testing technology for summer and winter tires for passenger cars, vans and 4x4s.

The most exact process for braking tests

On the outside, AIBA is a 300 meter long and up to 30 meter wide hall at the Contidrom, Continental’s main test center located in the Südheide (South Lüneburg Heath), about 35 km northeast of Hanover (fi gure 1). Packed full of highly compli-cated technology on the inside, unmanned test vehicles are accelerated fully automatically to up to 120 kilometers per hour and then braked on hydraulically interchangeable road sur-faces. AIBA thereby makes possible year-round tire tests under fully air-conditioned test conditions on various road surfaces (fi gure 2).

One core element of the test system is the fully automatic guidance and acceleration system, which was developed and constructed for Continental Hanover by ART Engineering GmbH. ART Engineering is an engineering offi ce for machine and system construction which has specialized in the design, development and construction of systems and rides for amuse-ment parks. With this know-how, the company was predes-tined for implementing the unique, steel-construction challenge of the AIBA guidance and acceleration system.

LIKE IN A ROLLER COASTERBar code positioning systems from Leuze electronic in the world’s fi rst automatic tire testing facility at Continental.

8

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“After all, we accelerate masses in excess of 3 metric tons from zero to 100 kilometers per hour in less than 5 seconds,” explains Georg Behringer from ART Engineering in Oberried. Actemium Freiburg Controlmatic GmbH took on the implementation of the primary system control on behalf of ART Engineering. Actemi-um Freiburg is an innovative service provider operating in the fi elds of Manufacturing Execution Systems (MES), automation, electrical engineering, instrumentation and control and analyti-cal chemistry and is a subsidiary of the French company VINCI Energies, one of the largest service providers for energy and information technologies in Europe.

Accelerations like in high-techroller coasters

Similar to high-tech roller coasters, the test vehicles are accel-erated to up to 120 kilometers per hour on a 100 meter track. The vehicles are guided on carriages by a tow-bar along a rail. The coupling on the vehicle allows for pitching movements by the vehicle to prevent the driving dynamics from being infl u-enced. “Acceleration takes place with a contactless linear drive, similar to those used in modern roller coasters,” explains Behringer. The highly accurate, full braking with ABS control is performed by a braking robot installed in the vehicle.

In addition to the acceleration and braking operation, the rail-mounted caddies also transport the test vehicles (fi gure 3). They are equipped with their own controls and receive their travel commands from the primary system control. The caddies couple to the carriages, position the vehicles for the launch, then collect them afterward and return them to the starting position. Coupling of the caddies is supported by sensors, which also come from Leuze electronic. They detect when the caddy approaches the carriage at a very short distance and output a signal for reducing the travel speed of the caddy.

Flexible and highly precise position determination of the caddies

“Taking into consideration the system length, a bar code posi-tioning system from Leuze electronic was the best solution for the unique position detection of the caddies,” explains Wegner. It is able to measure the positions with absolute precision independent of reference points and can thus provide unique position details at any time.

With the highly fl exible and hard-wearing bar code tape, the system can be used without problem over the entire test track (fi gure 4). Thus, the bar code tape along the guide tubes and the extremely compact bar code reader were the right and successful solution for the highly exact positioning.

Figure 2. The test runs in the fi rst automated, weather-independent tire

testing facility – AIBA – are performed on hydraulically interchangeable

road surfaces under fully air-conditioned test conditions.

Figure 3, right. Positioning and all transport

of the test vehicles in the AIBA is performed

automatically with caddies that communicate

with the system control.

Figure 1. The 300 meter long and up to 30 meter wide hall for the state-of-

the-art AIBA tire testing facility at the Continental Contidrom is packed full

of highly complicated technology.

Figure 4, left. In the AIBA, the positions of

the caddies for the test vehicle transport

are detected over the total length of the test

track via bar code positioning systems from

Leuze electronic.

9

“ONE SENSOR – TWO PROTECTIVE FUNCTIONS – ENORMOUS SCANNING RANGE!”The new RSL 400 safety laser scanner family: two autonomous protective functions, a scanning angle of 270° and operating range of 8.25 m.

HIGH-PERFORMANCE

270° scanning angle and

operating range of 8.25 m

Its large scanning angle in combination with large

operating range enables reliable safeguarding,

even at corners and edges. As a result, a second

laser scanner is not needed in many cases.

USER FRIENDLY

Intelligent connection unit

The simple mounting of the safety laser scanner

is based on a separate unit with integrated cable

management. This unit also makes possible fast

device upgrades or sensor replacement without

electronic and mechanical realignment.

With the new RSL 400 safety laser scanner, we have set a new standard worldwide in the supreme disci-pline of safety sensor technology. With our decades

of experience, we have succeeded in developing a device that uses clever detailed solutions to – in many cases – perform two tasks simultaneously.

FLEXIBLE

Two autonomous protective functions

The device offers two independent protective functions

and thereby acts as two single laser scanners.

You save yourself one device!

SMARTER APPLICATION KNOW-HOW

Further information on our new,

added-value features on pages 16 / 17

easy handling.

Its large scanning angle in combination with large

operating range enables reliable safeguarding,

even at corners and edges. As a result, a second

laser scanner is not needed in many cases.

The simple mounting of the safety laser scanner

is based on a separate unit with integrated cable

management. This unit also makes possible fast

device upgrades or sensor replacement without

Two autonomous protective functions

The device offers two independent protective functions

and thereby acts as two single laser scanners.



handling.

10

“ONE SENSOR – TWO PROTECTIVE FUNCTIONS – ENORMOUS SCANNING RANGE!”The new RSL 400 safety laser scanner family: two autonomous protective functions, a scanning angle of 270° and operating range of 8.25 m.

MAXIMUM PERFORMANCE WITH MINIMUM EFFORT!

It has never been easier to use a safety laser scanner than with the new RSL 400. In spite of exceptional performance charac-teristics, mounting, alignment and operation are unmatched in this segment.

Separate connection unit with integrated cable management for uncomplicated mounting

Large, plain-text display with electronic spirit level for simple alignment

Integrated Ethernet interface makes devices fully network capable Sensors are demonstrably very robust against dust thanks to high resolution

Removable scanner unit for simple device upgrades and replace-ment without re-alignment, re-adjustment and configuration work

11

Rolf Brunner,Head of Product Center – Laser Scanners

Profi t from two autonomous protective functions, scanning angle of 270° and operating range of

8.25 m.

A WORLD FIRSTTo the animation clip

11

The impulsive and lightning-fast movements of automatic pipe-bending machines are rem-iniscent of the fast and precise moves seen in breakdancing. But unlike breakdancing, where only the acrobatic dancers themselves are at any risk of relative danger, the hazard to the operator in the workspace of a pipe-bending machine is much greater. For this reason, SMA Metalltechnik equipped all bending machines with safety laser scanners from Leuze electronic.

Effective and fl exible safety concept

“Over the many years, machinery with various structures and a wide range of safety concepts has been designed,” explains Kurt Wiesenauer, director of maintenance at SMA.

Most of these systems require manual feeding of the pipe blanks into the respective clamping devices and the removal of the fi nal, bent pipes. To safeguard the workspaces, Wiesenauer searched for a simple-to-install and effective, yet fl exible, safety concept in order to be able to easily upgrade the existing systems with their respective conditions without mechanical additions or conversions.

When pipes artfully appear from a fast and perfectly swiveling bending head – as if being bent freely in space – the short and impulsive movements in the working range of semi- or fully automatic pipe-bending machines have little entertainment value. Rather, they pose a considerable hazard to the operator (fi gure 1).

At SMA Metalltechnik GmbH & Co KG in Backnang, an entire hall of such ‘breakdancers’ perform their moves. The company has been developing and producing aluminum piping for more than 20 years. The precisely designed, shaped, bent and soldered pipes are used to carry a wide range of materials, such as water, oil, gasoline, coolant or air, from point A to point B. In addition to heating, cooling and air-conditioning technol-ogy, products from SMA are used above all in the automotive industry and in machine construction.

Figure 1. Danger point: the bending head.

Figure 2. A bending cycle cannot be started until enabled by means of

two-handed operation outside of the protective fi eld.

SAFER DANCE FLOOROptical safeguarding of the workspaces at pipe-bending machines.

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Effi cient protective fi eld design

Wiesenauer found a perfect solution in the safety laser scanners from Leuze electronic. The ROTOSCAN RS4 devices represent a particularly fl exible variant of optical danger zone safeguard-ing. They also guard the so-called stepping-behind area. A bending cycle cannot be started until enabled by means of two-handed operation outside of the protective fi eld (fi gure 2).

As area scanners, the ROTOSCAN RS4 safety laser scanners are type 3 electro-sensitive protective equipment that can reliably detect a body, leg, arm or hand in freely confi gurable protective fi eld contours. On the pipe-bending machines at SMA, the laser scanners are mounted on the ground, where they horizontally scan the entry area like a radar (fi gure 3). The protective fi eld contours can be freely defi ned here. If objects are permanently located in the scanning range, such as the material boxes for completed parts at SMA, these are virtually suppressed from the scan area through programming (fi gure 4).

Figure 4. The containers located

within the protective fi eld are virtually

suppressed from the scan area.

Easy to install

All device parameters and protective fi eld contours can be easily adapted to the local conditions and to the required safety distances with the graphical interface of the easy-to-use RS4soft confi guration and diagnostics software. If different protective fi eld geometries need to be set up due to, e.g., product changes, this can also be performed quickly and easily. If an employee now enters the protective fi eld of a pipe-bending machine during automatic operation or if an object penetrates the fi eld, the “moves” are stopped immediately and reliably.

Figure 3. ROTOSCAN RS4 safety laser scanners protect the operators.

They safeguard the danger zones at the pipe-bending machines. The

protective fi eld at each pipe-bending machine is marked by colored tape.

The protective fi eld geometry is defi ned by means of parameter settings

that remain stored in the Confi gPlug connector plug.

In the future, you will be able to solve these and many other tasks even more effi ciently with our successor product, the RSL 400.

suppressed from the scan area.

In the future, you will be able to solve these and many other tasks even more effi ciently with our

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FOUR POINTS SHOW US THE WAY!The new DDLS 500 optical data transceiver makes mounting and alignment easier than ever.

SMARTER PRODUCT USABILITY

INTEGRATED

Integrated laser alignment aid

Four laser spots on the fl oor aid in easily aligning

the device, even over longer distances.

CONTROLLED

availabilitycontrol

Constant monitoring of the receiving level means

that the user can be alerted to an impending failure

(e.g. as a result of excessive soiling) in good time.

Optical data transceivers are the right choice for any application where data needs to be transmitted without cables and without interference. They enable contact-free and wear-free optical communication wherever mechanical systems are pushed to their technical limitations.

In addition to their basic function – optical data transmission – the DDLS 500 devices offer other functions. These revolutionize and considerably simplify operation, commissioning, and diagnostics – that is SMARTER PRODUCT USABILITY like only Leuze electronic offers.

PATENTED

One-man alignment

With the patented single-hand adjustment

process, precise alignment of the data light beam

is possible by a single person.

easy handling.Further information on our new,


Four laser spots on the fl oor aid in easily aligning

Constant monitoring of the receiving level means

that the user can be alerted to an impending failure

(e.g. as a result of excessive soiling) in good time.

With the patented single-hand adjustment

process, precise alignment of the data light beam

easy handling easy handling easy .Further information on our new,


14

FOUR POINTS SHOW US THE WAY!The new DDLS 500 optical data transceiver makes mounting and alignment easier than ever.

FAST, MODULAR AND ALWAYS IN THE PICTURE

Through the modular basic design, all functions can be fl exibly arranged depending on requirements. Thus, the devices do exactly what is needed and thereby offer an optimum price/performance ratio. With real-time, 100 Mbit/s optical data trans-mission, all common Ethernet protocols can be transmitted without time delay over a distance of up to 120 m. The DDLS 500 thus supports, e.g., Profi net, EtherNet IP, EtherCat, Ethernet TCP/IP, Ethernet UDP and many others.


For better alignment, the device projects four

laser spots on the fl oor along the intended

light path. An integrated attachment plate with

alignment screws makes both mounting and

fi ne adjustment quick and easy.

15

AND NOW YOU CAN BENEFIT!For our “smarter product usability” we use many different technologies and solutions. Exactly that is the source of your added value.

easy handling.

power reserve.


We give this designation to products that can convince with intelligent ideas for mounting and alignment or solutions for reliable and simple oper-ation of the devices. This includes, e.g., technologies such as the intelligent omnimount fastening concept, the especially large and bright brightvision light spot for alignment or active ambient light suppression A²LS.

Of what use is the most powerful sensor if just minimal deviations in distance or cleanliness prevent the device from properly functioning? We use different technologies depending on the device in order to ensure a maximum performance reserve in the devices. This improves your fl exibility and your processes run more stable.

System standstills due to soiled sensors need not happen. These devices emit a warning message in good time before there is a loss in performance and sensors fail due to soiling. As a result, they can be cleaned in a timely manner and costly system standstills avoided.

think modular.Are you looking for a device that is as individually tailored to your requirements as possible? With our thinkmodular concept, you can choose various equipment features from select devices and thereby assemble the right function range yourself. The result is a device that is optimally adapted to your application.

availabilitycontrol.

16

AND NOW YOU CAN BENEFIT!For our “smarter product usability” we use many different technologies and solutions. Exactly that is the source of your added value.

integrated connectivity.A sensor, regardless of the operating principle on which it operates, is always just a small part of a complex control system. For this reason, the maximum and simple compatibility with common fi eldbus environments is a basic requirement of all of our developments. Product names that include integratedconnectivity or the italic “i” designate devices that are equipped with extensive, integrated interfaces and which, as a result, greatly simplify implementation for you.

17

ALWAYS KNOW WHERE YOU AREWe position objects – with millimeter accuracy over distances of up to 10 kilometers.


The new generation of the BPS 300i bar code positioning system with a broad range of selectable equipment, integrated fi eldbus interfaces and the

availabilitycontrol functionality for ensuring read quality.

WELL DESIGNED

Simple mounting

A clever mounting system greatly simplifi es

the installation and replacement of the device.

INSENSITIVE

Reliable functionality

The device constantly signals its performance

reserves with the integrated availabilitycontrol

and thereby indicates, e.g., soiling in good time.

Furthermore, a large working range of ± 60 mm offers

suffi cient performance reserves, even if there are

mechanical fl uctuations.

INTEGRATED

PROFIBUS fi eldbus interface

The PROFINET fi eldbus interface already integrated in the device

makes start-up and confi guration quick and easy. NEW: PROFIBUS / SSI

Further information on our new, added-

value features on pages 16 / 17

availabilitycontrol.



NEW:



control



NEW: PROFIBUS / SSI

control.

18

19

ALWAYS KNOW WHERE YOU AREWe position objects – with millimeter accuracy over distances of up to 10 kilometers.

NO POSITION DETECTION, NO AUTOMATION

Many automation processes are only feasible if the position of an object is known at all times. Regardless of whether, e.g., skids report their position with millimeter accuracy by means of a bar code positioning system and a bar code tape up to 10 km in length or a simple refl ection light scanner that aids in ensuring the correct column and shelf positioning in a high-bay warehouse, our devices always perform these tasks reliably.


DESIGNED FOR PERFECTIONLSIS 400i smart cameras in the automated door assembly in vehicle body construction at Audi.

20

Figure 1. LSIS 400i smart camera systems at the fully

automated door installation stations designed for

perfection in the vehicle body construction facilities for

the new Audi A3.

IN ONE OF THE WORLD’S MOST MODERN VEHICLE BODY CONSTRUCTION FACILITIES, LSIS 400i SMART CAMERA SYSTEMS MONITOR THE HINGE BOLT HOLES DURING FULLY AUTOMATIC DOOR INSTALLATION.

“The vehicle body construction plant for the new Audi A3 is a new, highly effi cient factory for a new, highly effi cient automo-bile!”

This is how Audi describes the development of the A3 body to interested visitors within the scope of a fascinating guided tour through the production facilities. As a matter of fact AUDI’s largest production location at the company’s headquarters in Ingolstadt is one of the most modern production facilities in the automotive industry. Here the company produces the models for the Audi A3, Audi A4, Audi A5 and Audi Q5 series (fi gure 1).

While visitors follow the steel parts through their process steps and marvel at the future of vehicle body construction as they glimpse at the world’s most modern body units, innovative technologies provide for perfect quality results. This includes, for example, the fully automatic door installation station realized here.

Special requirements for a reliable process

Automatic door installation is the fi rst assembly step on the so-called attachment part line which the vehicle bodies pass through on walk-on, sliding platforms (fi gure 2). Here, attach-ment parts, such as doors, hoods and hatchbacks, fenders, etc., are mounted primarily by hand.

Because the bodies are not ideally positioned for automation in this area, they must be measured using certain features to determine the exact position for the automated door installa-tion. The fi nal correction values for the robot equipment are calculated from this position data. In addition, the hinge bolt holes (fi gure 3) are checked with the smart camera systems of the LSIS 400i series from Leuze electronic.

Continued on page 22

21

Everything in one unit

“The challenge was to fi nd a system that, in spite of the great camera distance, could recognize the bolt holes with certainty while also checking multiple holes simultaneously to minimize the number of devices,” summarizes engineer Dirk Kaufmann, planner in the area of automation technology for vehicle body construction at Audi in Ingolstadt (fi gure 4).

LSIS 400i smart cameras have the advantage that they combine all required components from image processing to illumination, data storage and interfaces as well as a display for operation and viewing results in one unit (fi gure 5).

Figure 3. The bolt holes for the hinges on the

Audi A3 bodies are checked to ensure absolute

process reliability at the automated door

installation station.

Figure 2. The large camera distances are

dictated by the dimensions of the walk-on,

sliding platforms and the operating radius for

the robots.

Figure 5. With sturdy metal housing: Thanks to their excellent

performance, only two smart cameras are required on each

side of the body for a total of eight regions of interest.

22

Sven-Philipp Abraham, Product Manager – Industrial Image Processing

BLOB analysis with region of interest tracking

With their image evaluation right down to the last pixel the LSIS 400i cameras provide an absolutely reliable solution for checking the bolt holes. The smart cameras use a so-called BLOB (Binary Large OBject) as a detection tool.

A signifi cant performance feature of the smart camera systems from Leuze electronic is the so-called ROI mode for tracking Regions Of Interest. For each hinge there are two bolt holes to be checked – one larger hole without thread and one smaller hole which is already threaded.

Due to the distance as well as the refl ection characteristics of the thread and material, recognition of these bolt holes is a very demanding task, also due to the varying contrast differences, particularly because the bodies are not clearly positioned to a suffi cient extent on the conveyor system’s sliding platforms, as already described previously.

For this reason the larger bolt holes are recognized and checked fi rst, because of their higher contrast. Then, after the exact positions are known, the regions of interest for the smaller bolt holes can be repositioned. The LSIS 400i smart cameras thereby ensure reliable detection of the hinge bolt holes.

Figure 4. In spite of the great camera distances the LSIS 400i

series smart cameras recognize the bolt holes for the hinges

in the A and B-pillars on the Audi A3 bodies with absolute

reliability even at an angular position.

Sven-Philipp Abraham, Product Manager – Industrial Image Processing

23


With its wide light-band, the new RK 46C VarOS retro- refl ective photoelectric sensor very reliably detects small and large objects, even with gaps.

The integrated ALC sensitivity readjustment also ensures a constant performance reserve even in the event of soiling.

VERSATILE

Large detection range

The wide light-band detects in a 45 – 60 mm-wide area and,

as a result, can replace expensive light barriers or multiple

individual sensors.

EASY

Confi guration at the touch of a button

Simple adaptation of the sensitivity / resolution to two object

sizes from 8 mm by means of 2-level teachme function by

pressing a button on the rear of the housing.

INTUITIVE

Visible light-band for alignment

A highly visible brightvision light-band makes alignment quick

and easy.

TOLERANT

Detection of objects with openings

This sensor responds to objects within the total width of its

light-band and, as a result, can also reliably detect objects

with holes or interruption.

THIS LIGHT-BAND CAN DETECT EVERYTHING – ROUND, ANGULAR, GLOSSY, WITH GAPSThe new RK 46C VarOS retro-refl ective photoelectric sensor.



power reserve.

The wide light-band detects in a 45 – 60 mm-wide area and,

as a result, can replace expensive light barriers or multiple

Simple adaptation of the sensitivity / resolution to two object

function by

light-band makes alignment quick

This sensor responds to objects within the total width of its

light-band and, as a result, can also reliably detect objects



reserveFurther information on our new,

reserve.

24

Oliver Bunz,Head of the Product Center – Switching Sensors

THIS LIGHT-BAND CAN DETECT EVERYTHING – ROUND, ANGULAR, GLOSSY, WITH GAPSThe new RK 46C VarOS retro-refl ective photoelectric sensor.

WE CAN DO BOTH NORMAL AND OUT OF THE ORDINARY!

Round, angular or both – with glossy surfaces or with transparent shrink-wrapped fi lm – completely black, with gaps or high levels of ambient light. Whenever the object that is to be detected or the environmental conditions deviate from normal, these sensors are at their best. Depending on the application, a wide range of technologies ensure reliable detection of the objects.

SIMPLY FIND THE RIGHT PRODUCT: WWW.LEUZE.COM

Head of the Product Center – Switching Sensors

CAN DETECT EVERYTHING –

Round, angular or both – with glossy surfaces or with transparent shrink-wrapped fi lm – completely black, with gaps or high levels of ambient light. Whenever the object that is to be detected or the environmental conditions deviate from normal, these sensors are at their best. Depending on the application, a wide range of technologies

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For more than 25 years, Leich und Mehl GmbH Weighing and Labeling Technology from Kernen in the Rems valley (SW Germany) has been setting standards for weigh-price labelers used for packaging in industrial food production, from meat and cheese to fruit and vegetables (fi gure 1).

“Quality is refl ected in the precise and clean appearance of the printed labels which are correctly positioned and, ultimately, can be scanned reliably at the supermarket checkout”, says Managing Director Dr. Mehl, referring to the company’s own highly developed printer technology. The newest generation of weigh-price labelers, the PAW 2000, is designed and approved

to perform up to 160 labeling operations per minute at a print-ing speed of up to 300 mm/s. The sensors used in the labelers, especially the forked sensors and bar code readers from Leuze electronic, make a signifi cant contribution to operating performance.

Precise detection of labels

With their extremely short response times and very high repetitive accuracy, the GS 61 forked sensors ensure precise detection of the labels on the backing fi lm as well as an accu-rate printing position even at high speeds (fi gure 2). “The more precisely the beginning and end of the labels can be detected, the more accurate the print will be”, stresses Thomas Steudle, Service Manager at Leich und Mehl.

LABELING PERFECTIONForked sensors and bar code readers from Leuze electronic support the reliability of Leich und Mehl weigh-price labelers.

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What he particularly likes is the fact that with just one basic setting the GS 61 forked sensor is able to reliably detect a broad range of labels with different colors and on all types of backing fi lm. “We set up the sensor once using the convenient potentiometer. So far, it has been necessary to readjust the sensor for the customer on only a few rare occasions”, adds Steudle.

An equally decisive reason why Leich und Mehl opted for the GS 61 forked sensors is their extremely compact design: They are worldwide the smallest optical forked photoelectric sensors in industry quality used for labeling technology. With a mouth width of just three millimeters and an extremely fl at low-er fork leg in the new slimline design, they can be integrated in systems where very little installation space is available. A clear-ly visible marking allows the label tape to be aligned quickly.

Uniquely compact

Size – or more precisely compactness – was also a decisive factor for choosing the Leuze electronic BCL 8 bar code readers (fi gure 3). Integrated in the printer housing of the PAW 2000 weigh-price labeler, the device checks whether the bar code is legible immediately after it has been printed. With their ultra-compact dimensions, the BCL 8 bar code readers fi t between the tightly arranged fi lm strips in the PAW printers. Thanks to a robust metal/glass housing and the M12 connec-tor, the bar code readers have degree of protection IP 67 and are ideal for use in industrial applications.

Depending on the requirements, the BCL 8 devices can option-ally also be installed outside the printer at the point where the products with the new label leave the machine. The devices can be positioned such that they scan the products from above as well as below in cases where labels have to be attached to the underside of packaging. The scanners are then additionally used to check whether the labels have actually been attached to the packaging. “In some cases, this also involves checking whether the preprinted bar code is the correct one”, adds Steudle.

Ideal solutions to meet the demands of every application

It is often the case that a mixture of different products have to be weighed and labeled on the PAW 2000. In systems intended for this purpose and for which Leich und Mehl employs a modular design to meet the individual needs of its customers, there is an additional bar code scanner installed at the infeed conveyor line. This scanner detects the incoming products using a bar code that has already been attached, so that the label with the correct information can be printed in the printer. Leich und Mehl uses the bar code readers of the BCL 300i series for this task (fi gure 4).

With ranges up to 700 millimeters, this device generation is ideal for detecting different products with varying packaging sizes (i.e. reading heights). Once again, the comparatively compact design is of advantage: It means that the device can be positioned very close to the conveyor line.

Figure 2. The GS 61 from Leuze electronic is the smallest optical forked

photoelectric sensor in industry quality worldwide and, with its slimline

design, fi ts easily in the printer housing of the PAW 2000.

Figure 1. The weigh-price labelers from Leich und Mehl are regarded as

premium products in the branch.

Figure 3, left side, large photo. BCL 8 bar code readers check the bar code.

Figure 4, left side, small photo. Bar code readers of the BCL 300i series

detect products of varying sizes as they enter the labeler.

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WE’VE SIMPLY DONE AWAY WITH ALIGNMENT! THE NEW PRK 18B


FAST

Extremely short jitter time

Precise repeatability thanks to a jitter time of just 32 μs.

INTEGRATED

Diverse mounting options

The threads integrated in the housing and the calibrated abeam

optics save 80 % additional material and make initial mounting and

device changes fast and uncomplicated.

We are leaders in performance and usability with our sensors of the 18 series. The retro-refl ective photo-electric sensors of the 18B series go a step further

with numerous smart ideas and offer solutions that are unmatched in terms of handling and mounting as well as speed and performance.

easy handling.

Precise

Calibrated optics

The calibrated abeam optics precisely strike even small refl ectors

without time-consuming alignment.



abeam

optics save 80 % additional material and make initial mounting and

handling.

optics precisely strike even small refl ectors

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WE’VE SIMPLY DONE AWAY WITH ALIGNMENT! THE NEW PRK 18B

OUR SENSORS ARE SIMPLY BETTER AT DETECTING TRANSPARENT MEDIA

When it comes to the reliable detection of partially and highly transparent objects, sensors need to show what they are really capable of. Systems don’t demonstrate their true performance until put to daily use. With our solutions, we can extend the cleaning cycles for sensors used in the detection of transparent media, e.g., from one week to up to a year.

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Dr. Marie-Theres Heine, Product Manager – Switching Sensors


When it comes to the reliable detection of partially and highly

performance until put to daily use. With our solutions, we can extend the cleaning cycles for sensors used in the detection of transparent media, e.g., from one week to up to a year.

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Dr. Marie-Theres Heine,

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Continental Safety Engineering International in Alzenau obtained the support of the safety experts from Leuze electronic for the imple-mentation of a suitable safety concept for a crash simulation system and the required CE certifi cation.

The crash simulation system at Continental Safety Engineering in Alzenau, a subsidiary of the international automotive supplier Continental, is part of a complete test infrastructure based on the state of the art (fi gures 1 and 2). In addition to the test track – the Continental Safety Park – a vehicle crash system and a crash simulation system are at the center of the facilities.

While the vehicle crash system accelerates or drives vehicles or vehicle prototypes against a crash block, moving barriers or other vehicles, the crash simulation system, in the form of a servo-hydraulic, controlled sled system, is used to perform tests without destroying expensive vehicles (fi gure 3). “We realistically recreate deceleration processes from complete vehicle tests, basically as an inversion function by accelerating a sled with the appropriate test structure,” explains Martin Kahlert, the team leader responsible for the sled system.

Life-threatening danger with no time to respond

An acceleration distance of 1,700 mm suffi ces in the sled system. At this distance, a nominal force of 2,500 kN is avail-able which is used to catapult a maximum test weight of 3,000 kg plus the weight of the sled and piston 1,500 kg, – at 60 times the acceleration due to gravity. In this short time, sled speeds of up to 90 km/h are reached. The accelerations of the enormous masses for the simulation tests occur in just millisec-onds, from zero to a maximum value. Even in the area near the tracks at the end of the system, on which the sleds are braked within 1.0 to 1.5 seconds, an employee present in this area would not have time to respond. He would not even notice the danger to life headed towards him. That is precisely the reason for the high classifi cation according to Performance Level d.

Well-advised with Safety Consulting

For this reason, all employees must exit the hall prior to every crash simulation and it must be ensured that absolutely no one can enter for the duration of the test. Due to the size of the hall (fi gure 4), which includes some diffi cult-to-see areas, and the various doors and gates, a sophisticated safety concept is nec-essary. This was realized with support as well as safety compo-nents from Leuze electronic. At its center is the so-called “clearing of the hall” – a precisely defi ned routine, according to

TOP PRIORITY: NO INJURIES!Safety engineering for a crash simulation system at Continental.

Figure 1. The crash simulation system is part of a complete test infrastructure based on the state of the art at Continental Safety Engineering International.

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which the system operator in charge personally locks all entrances from the inside in sequence and within specifi c time windows.

Focus of the Safety Consulting project was on the development and implementation of a suitable safety concept. This also involved the implementation of a safety controller, including the necessary components, such as safety locking devices for the doors, additional magnetically coded sensors and safety relays – everything from Leuze electronic. Here, the SISTEMA and Safexpert software programs were used to effi ciently perform the CE certifi cation with the objective of producing the Declara-tion of Conformity.

Tips from the experts

Serving as the basis for the entire safety concept was an on-site, joint assessment of the current, individual safety situation. “For us, one of the main components was the training for programming the MSI safety controller with the MSIsafesoft programming software. The safety experts from Leuze electronic could give helpful tips here that are necessary for a project of this magnitude,” adds Kahlert.

On the hardware side, it is mainly the MSI safety relays which contribute to a simple implementation of the safety application through a combination of innovative connection technology, compact and space-saving designs and well-arranged housing design. They function as monitoring and integration compo-nents for the L200 safety locking devices (fi gure 5) used on the doors and gates to securely lock all safety doors and thereby prevent the unauthorized entry of persons during a crash simulation. In addition to this, all doors are also monitored by MC 300 magnetically coded sensors as specifi ed due to the high Performance Level (fi gure 6).

“With Leuze electronic, we have found a partner who has ac-companied us with a great deal of application experience over the entire CE certifi cation and risk assessment process in the integration of a best-possible safety concept that offers optimum safety, taking into account the relevant standards and regulations,” says up Kahlert.

Figure 2. Continental Safety Engineering International – a subsidiary of the inter-national automotive supplier, Continental – has committed itself to the develop-ment of systems for active and passive vehicle safety.

Figure 3. In the crash simulation system, developments and testing of frontal, side and head air bags, vehicle and child seats, belt systems and other interior equipment take place.

Figure 4. Due to the size of the hall that houses the crash simulation system at Continental Safety Engineering International in Alzenau, a sophisticated safety concept is necessary. This was realized with support and safety components from Leuze electronic.

Figure 5. Heavy-duty L200 locking devices were mounted in front of the doors to ensure that no one can enter during the dangerous test.

Figure 6. Behind the doors, MC 300 magnetically coded sensors perform position monitoring and thereby ensure the required Performance Level.

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Leuze electronic GmbH + Co. KG

In der Braike 1

D-73277 Owen / Germany

Phone +49 7021 573-0

Fax +49 7021 573-199

[email protected]

www.leuze.com

Imprint:

Issuer: Leuze electronic GmbH + Co. KG

Marketing and Communication

Editors: Volker Aschenbrenner

(responsible editor)

Thomas Röhrle

Matthias May

Concept and design: blösch.partner, Eppingen

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