Sensor Solutions For The Automotive Industry

INDUSTRY GUIDE
Sensor Solutions
for the Automotive Industry
Process Optimisation in Every Detail

Becoming better, together.
Leading-edge sensor technology

for the entire production process
The optimisation of operations in automotive production is a

continuous task. After all, global competition and price pressures
do not disappear. Therefore, every detail is always crucial.
SICK sensor technology helps to exploit potential efficiencies.
As an independent and world-leading developer and manufacturer

of intelligent sensor systems SICK has for many years made a vital
contribution to process optimisation in the automotive industry.
SICK sensor solutions are part and parcel of making the entire pro-
duction environment safer, faster and more transparent. Hazards
and problem sources are systematically eliminated; individual pro-
duction steps are accelerated by increasingly accurate, sensor-based
controls. Thus, with its comprehensive sensor competence, SICK
provides convincing solutions in quality assurance and maximum
manufacturing transparency.
All of this to make you one of the first in the global race within
the automotive industry.
Global Presence
Complete Sensor Supplier
Leading Innovator
Service Solutions
Online Partner Portal for
the Automotive Industry
2 AUTOMOTIVE INDUSTRY | SICK

Sensor benchmarks
for the automotive industry
On the following pages, you will find an

overview of SICK’s capabilities and
the most common sensor applications
in all stages of automotive production.
Let’s concentrate on the areas in which
SICK “Sensor Intelligence” can make
your production even more efficient.
Together, we can discover your optimi-

sation potential and develop individual
solutions with you for increased compe-
titiveness.
CONVINCING PERFORMANCE
Global Presence 04
Complete Supplier 06
Sensor Milestones 08
International Service Solutions 10
Online Partner Portal 12
EXEMPLARY
SENSOR SOLUTIONS
Press Room Sensors 18

Body in White Sensors 28
Sensors in Final Assembly 36
Sensors in Engine
and Gearbox Production 44
Network Technology 52
SICK | AUTOMOTIVE INDUSTRY 3

Global presence.
Because the industry knows no limits
In the automotive industry, it’s the global perspective

that counts. Thus, SICK are represented worldwide too.
As an independent partner, we are always on your side
and quickly available. No matter where in the world you
are. SICK is near you: with more than 40 national and
international subsidiaries, many agencies and partner-
ships.
In addition to distribution and service, SICK is geared to

international production and development … strategically
placed and customer-oriented, across Germany, Italy,
Sweden, Japan and the USA … making us even closer to
many different industry developments.
As an innovative complete sensor supplier with worldwide

leadership, we are thus committed to our self-image and
to our customers: always one step ahead in technology,
around the world.
Benefit from SICK’s worldwide presence. Always and

everywhere.

Around the World WORLD - CLASS LOGISTICS
Europe America Asia

• Austria • Argentina • China In essence, our own logistics are
• Belgium • Brazil • India among our best references …
• Czech Republic • Canada • Indonesia where we show how complex
• Denmark • Chile • Japan distribution can operate using
• Finland • Mexico • Korea intelligent sensor solutions and
• France • USA • Malaysia sophisticated concepts.
• Germany • Venezuela • Singapore
• Great Britain • Taiwan The international SICK logistics
• Hungary • Thailand centre reduces delivery times,
• Italy service and storage costs.
• Luxembourg Africa Australia We take components and spares
• Netherlands • South Africa to the right place, at the right
• Norway time – to you. And to your benefit!
• Poland
• Portugal
• Romania
• Russia
• Slovakia
• Slovenia
• Spain
• Sweden
• Switzerland
• Turkey
The complete supplier for complex solutions.
“Sensor Intelligence”, integrated
SICK has long recognised the key role sensors play in fac-
tory automation and have developed application-oriented
sensor products. Meanwhile, this has evolved into highly
complex sensor solutions which are more than mere
“signal transducers”. Our claim is innovative “Sensor
Intelligence”, for good reasons: complete systems which
combine safety and control functions.
This integration is perfectly illustrated for the automotive

industry, e.g. by UE1000 series safety bus modules:
solutions for machines and systems with a high degree
of networking. A SICK innovation from the Industrial Safety
Systems Division. However, developments also continue
in the two other SICK Divisions of Industrial Sensors and
Auto Ident and with ever-increasing speed.
This, of course, is of particular benefit to you. With “Sensor

Intelligence”, your processes achieve a degree of optimi-
sation unheard of only a few years ago. And you have all
the positives on your side: quality, efficiency and manufac-
turing transparency.
Combine safety and control to achieve complete inte-

gration – with systems, products and services from SICK.
INDUSTRIAL SENSORS
Encoders, ultrasonic sensors, inductive, capacitive

and magnetic proximity sensors as well as magnetic
cylinder sensors, photoelectric switches, contrast
and luminescence scanners, colour sensors, fork
sensors, light grids, distance sensors, data trans-
mission systems, vision sensors, position finders
and split-beam sensors

Photo:Daimler Chrysler AG
INDUSTRIAL SAFET Y SYSTEMS AUTO IDENT
Photoelectric safety switches, safety light curtains, Stationary 2D code and bar code scanners, hand-
safety laser scanners, safe camera systems, safety held scanners for mobile and stationary use,
switches and safety software. The range comprises omnidirectional bar code reading systems, indoor
commissioning, safety checks, repair and exchange and outdoor laser measuring systems, evaluation
service, stop time measurements, technical con- electronics, bus connection systems, software
sultancy, education und training tools, engineering

SICK highlights in the Automotive Industry.
Sensor milestones
Technology does not evolve by itself. Progress only comes

about when we constantly go beyond what is known, deve-
lop new ideas and take them to the market.
Such as at SICK!
SICK has always invested more than most in research and

development. They are the engine of sensor development
and our worldwide success. The results are impressive:
sensor milestones which have opened up ever-new oppor-
tunities for process optimisation in automotive construc-
tion. Innovations which deserve their names and have
made a decisive contribution to the technological progress
in the automotive industry.
Something which in 1950 began with the first practical

photoelectric switch, based on the autocollimation prin-
ciple, has certainly not finished with the most recent
generation of milestones – laser scanners, light curtains, S3000 – PIONEER OF A
smart cameras and image code readers. NEW DIMENSION IN LASER
ME A SURING TECHNOLOGY
Trust the leading innovator for complete sensor solutions.
With SICK your production will set benchmarks for the The S3000 safety laser scanner sets
whole industry too. new standards in measurement accu-
racy and variety of use. It can be used
for the protection of horizontal and
vertical hazardous points, hazardous
areas and access according to type 3
LEADING of IEC/EN 61496-3.
IN EACH DISCIPLINE
• Protecting
• Preventing collisions
• Navigating
• Measuring
• Positioning
• Identifying
• Sorting
• Picking
• Integrating

C4000 – IVC -2D/3D – ICR850 –
SELF-TEACHING HIGH-TECH 2D CODE SCANNER
S A F E T Y L I G H T C U R TA I N IMAGE PROCESSING SYSTEMS WITH HIGHER ACCURACY
Simply efficient: With the use of the All-in-one and for the first time also in The ICR850 Image Code Reader does
C4000 Entry/Exit system one sensor 3D: The freely programmable IVC-3D not require a code that is positioned
pair reliably distinguishes between smart camera sets standards for qua- exactly or a code-related trigger signal
man and machines. Add to this the lity assessments on assembly lines, and no additional lighting. Thanks
self-teaching variety of functions and robotic and handling processes. With to high resolution of 2,048 pixels, it
easy commissioning and this reduces a comprehensive library and sophis- is able to recognise codes down to a
assembly and running costs by up ticated image processing, it opens up few mm2 in size … something that did
to 40 % compared with conventional new, flexible and – above all – econo- not exist before.
systems. mical solutions.

Service over the lifetime of a machine.
From planning and operation

to modernisation
The particular issue of safety is certainly not completed

with fitting first-class SICK sensor technology. It begins
long before assembly and then just continues. After all,
safety with “Sensor Intelligence” is a continuous process
over the whole life cycle of machines and systems: from
planning and operation to modernisation.
With the “International Service Solutions” from SICK you

benefit at every stage. From the worldwide know-how of
the market leader in safety to the experience from various
industries and countless applications.
Use the “International Service Solutions” for more safety

and efficiency over the entire machine life cycle. More on
www.sick.com
TRAINING & CONTINUOUS T H E O N LY A C C R E D I T E D

E D U C AT I O N P R O C E S S O P T I M I S AT I O N M A N U FAC T U R E R
We have to know technology … to use We accompany you permanently. As SICK is the only manufacturer of sen-
it safely and fully benefit from the pos- soon as there are better solutions for sor technology accredited to perform
sibilities it offers. Learn about every- an area of your production, we will safety inspections of machinery and
thing through SICK training – from suggest them to you. Thus, we always systems ... one of the most coveted
the basics of safety technology to the maximise your sensor efficiency. official quality certifications.
implementation of complex safety
solutions.

SICK – Safety in All Phases of Factory Automation
SICK INTERNATIONAL SERVICE SOLUTIONS SICK INTERNATIONAL SERVICE SOLUTIONS
UPGRADE SERVICES A P P L I C AT I O N S U P P O R T
S A F E T Y A N A LY S I S
MODIFI- PLANNING
CATION ENGINEERING
DESIGN
INSPECTIONS COMMISSIONING
COMMIS- SUPPORT
SIONING
SIGN OFF TECHNICAL SIGN- OFF
MACHINE Commissioning check
STOP TIME MEASUREMENT
LIFE CYCLE
SAFET Y SIGN OFF
SERVICE CONTRACTS Inspection prior to first
commissioning
OPERATION
During the whole machine life cycle

T R A I N I N G & E D U C AT I O N PRODUCT SUPPORT

Working even more efficiently, online!
www.mysick.com —
Your Sensor Partner Portal
The Online Portal is a must where efficiency and fast pro-

cessing, in every detail, are paramount such as in the auto-
motive industry! At www.mysick.com you will find compre-
hensive eCommerce tools and information for your sensor
planning: complete project management from availability
check, quotations, ordering terms and conditions to order
placement/status. The SICK Partner Portal supports your
workflow, with the individual allocation of user rights.
With easy online access to sample applications as well as
the downloading of technical data, drawings and graphics,
your sensor planning is accelerated – effectively.
Sensor planning online – in the SICK Partner Portal
The big online product catalogue:

www.sick.com/productfinder
www.mysick.com
Clear:
Under the menu items of Products,
Information and “My Applications”
you will find everything you need for
your sensor planning.
Available 24 hours:
No matter where in the world you are
or when you want to know something.
At www.mysick.com, everything is only
a click away. Anytime!
Secure:
Your data is password-protected and
can only be seen by you. Using the in-
dividual user management, you can
define who is allowed to see what data
and what action to take!

YOUR BENEFIT S
I N T H E S I C K PA R T N E R P O R TA L
• Your work becomes even more efficient online

• The user management supports your workflow
• Product availability is shown immediately
• All operations are significantly accelerated,
e.g. price enquiries, quotations, orders
• Finding products, applications, circuits and
accessories is even faster
• Product search. Products and comprehensive
information technically linked
• All operations at a glance: product search,
Go online right away! quotation, order status etc.
• Exclusive download options: technical data,
drawings, graphics etc.
Price and availability query:

Simply and quickly deter-
mine the price and the de- Quotation enquiry:
livery date of the products You can enter a reference number for
required. your quotation. The quotations are Ordering online:
available to you online. Each quotation In a few steps, you can perform the process
is confirmed to you by email. of ordering equipment.

A P P L I C AT I O N S
Selected solutions to problems

for the Automotive Industry.
THE 4 PROCESS STEPS – AN OVERVIEW 16
1 ST P R O C E S S S T E P : P R E S S R O O M 18
Focus 1: Directing, controlling and protecting stacker cranes

Focus 2: Directing, regulating and monitoring the uncoiling operation
Focus 3: Protecting, positioning and monitoring body presses
Focus 4: Protecting, controlling and identifying in robot applications
2 ND P R O C E S S S T E P : B O D I E S I N W H I T E 28
Focus 1: Protecting and controlling turntables

Focus 2: Protecting and positioning in the area of vehicle floor assembly
Focus 3: Protecting, positioning and identifying in the area of robot cells
3 R D P R O C E S S S T E P : F I N A L A S S E M B LY 36
Focus 1: Work guidance and body identification in interior fitting

Focus 2: Protecting access to the assembly cell, locational and positional
control of rear/front screens
Focus 3: Positional control and collision protection on scissor lifts, backup control
and identification for the supply of wheels
4 TH P R O C E S S S T E P : E N G I N E A N D G E A R B O X P R O D U C T I O N 44
Focus 1: Protecting of processing machines and automatic loading stations

Controlling and monitoring of robot grabbers and workholders
Focus 2: Hazardous point protection of assembly robots
Lubricant control and component identification for quality assurance
Focus 3: Entry protecting of robot cells
Positioning and indicating of workpiece carriers
NE T WORK TECHNOLOGY 52

A P P L I C AT I O N S
Discover, step by step, how SICK

Sensor Intelligence makes your
operations even faster, more effi-
cient and safer.
We have illustrated the entire

production process. Using selected
examples, demonstrations of the
many different possibilities offered
by intelligent sensor solutions can
be shown. Be stimulated and find
out about your optimisation poten-
tial.
SICK support you in this.
The following applications only show the solution of

the tasks, schematically. Selecting the device types,
their arrangement and assembly must, especially in
areas of safety engineering, be matched to the task
and the conditions at the point of use. The represen-
tation of applications, the product properties given
and technical data do not constitute a warranty de-
claration.

THE 4 PROCESS STEPS – AN OVERVIEW
SICK offers sensor solutions

for all areas of automotive production.
1. PRESS ROOM
2. BODIES IN WHITE

THE 4 PROCESS STEPS – AN OVERVIEW
3 . F I N A L A S S E M B LY
4. ENGINE AND GEAR-

BOX PRODUCTION

1. Press room:
Assuring quality and meeting throughput targets
whilst maximising protection for man and machine.
In the production of body parts, quality and throughput targets must be right. Therefore,
SICK sensors are used in nearly all areas of the press room – with its many automated
press lines and robot assembly areas. They ensure maximum readiness to deliver and
direct the components and ready-to-fit systems to the production lines – at the correct
point in time.
• Storing sheet metal coils

• Taking coils out of storage
• Uncoiling the sheet metal
• Cutting sheet metal panels
• Punching and pressing
body parts
• Placing the punched FOCUS 1
parts in racks
FOCUS 2

PRESS ROOM
FOCUS 4
FOCUS 3

Press room, focus 1:
Directing, controlling and protecting
stacker cranes.
20
PRESS ROOM
The DME distance sensor determines the

horizontal position of the trolley of a
gantry crane. The vertical position of the
positive lifting gear is determined by an
ATM60 absolute multiturn encoder. The
IN4000 inductive safety sensor indicates
when the trolley has reached the limit
of the automatic range. Outside this range,
a worker controls the trolley and lifting
gear, by hand. All measuring sensors are
networked with the central control, via
Profibus.
The stacker crane is protected by S3000

safety laser scanners, in both directions
of travel. The protection (red) and warning
fields (yellow) have their size dynamically
adapted to the speed. The protection and
warning fields are switched over if the
direction of travel changes. The X axis is
positioned by the DME3000/5000 dis-
tance measuring device. Fine positioning
in the X and Y axes is performed by means
of a DMP position finder. The ISD300 data
photoelectric switch facilitates the stacker
crane/computer data exchange.
The DS60 distance sensor indicates that

a rack bin is occupied. It is insensitive to
reflections and features a particularly large
scanning distance.
The DMP2 position finder facilitates the

fine positioning of the stacker crane.
It allows the stacker crane to follow until
its receiver array is centrally lit by the
reflected light.
The i1000 safety switch locks the door to

the working cell. Opening the door triggers
a stop command for the stacker crane.
For long stacker crane stopping distances,
the locking device of the safety switch is
maintained by means of a safety time relay
until the stacker crane has come to a
standstill. This switch is designed for par-
ticularly arduous operating environments
and heavy doors.
AUTOMOTIVE INDUSTRY | SICK 21

Directing, regulating and monitoring
the uncoiling operation.
22
PRESS ROOM
The DS60 distance sensor indicates the

presence of a sheet metal coil.
Identifying the sheet metal coil prior to

processing, with the CLV450 code reader.
For instance, the type of material, sheet
thickness (gauge), web width etc. are
coded. The code reader, equipped with a
swivelling mirror, recognises the code in
a wide field of vision.
The DMT10 distance measuring device

continuously measures the diameter of
the coil. The measured values serve to
optimise the pull-off speed and start the
automatic coil changeover.
The MLG1 modular light grid detects the

sag of the sheet web for loop control:
adjustment of uncoiling speed and pull-off
speed. The beam coverage is output via an
RS485 interface.
The MLG1 modular light grid recognises

a hole > 15 mm, with which a weld is
marked. It signals the position of the weld
to the plate shear control.

Protecting, positioning and monitoring
body presses.
24
PRESS ROOM
The M4000 multiple light beam safety

device, consisting of sender and receiver
unit, protects the access to a hazardous
area. Three sides of a dangerous area can
be protected with two deflector mirrors.
The interruption of one beam or several
beams stops the hazardous movement
(here: movement of the press table).
A reset device positioned outside the
hazardous area enables the protective
field. This enables the restart of the press
table.
IQ40 inductive proximity sensors indicate

the correct positioning of the tool on the
press table, enabling automatic locking.
The IM30 inductive proximity sensor indica-

tes that the press tool is closed and can be
changed.
The S3000 safety scanner protects the area

in front of the press between two tool gates.
If there is a person or an object in this area,
extension or retraction of the tools is not
possible.
Two OD displacement sensors determine,

very precisely, the thickness of the sheet,
and report thickness deviations and double
sheets. In a subsequent control unit, the
measured values are evaluated. On the one
hand, the correct sheet thickness is checked
and, on the other hand, tool damage at
the following processing station is avoided
through double-sheet recognition.
Component control with a WT12 laser

photoelectric proximity switch. It indicates
that the part has been removed.
The i100P safety position switch indicates

the opening and closing of a sliding gate.
The use of high quality materials guaran-
tees reliable operation even in arduous
environments.

Protecting, controlling and identifying
in robot applications.
26
PRESS ROOM
The rack station in front of a robot cell is

access-protected by a C4000 safety light
curtain. If the rack is changed or if a per-
son steps through the light curtain, there
will be enforced interruption of the light
curtain and the robot will stop. However,
the C4000 is bridged, for the robot to be
able to continue work at another location,
during rack changeover. Simultaneously,
a second access protection behind the
rack station is primed and takes over the
safety function. It consists of an M4000
multiple light beam safety device and a
deflector mirror. If the M4000’s lightbeams
are interrupted, too, then the robot is
stopped. C4000 light curtain and M4000
multiple light beam safety device are also
mutually active.
Two WT9-2 photoelectric proximity switches

and four IM12 inductive proximity sensors
control the grabber of a robot for locating
a body part. MTZ1 magnetic cylinder
sensors recognise the piston position in
the pneumatic cylinders, with which the
grabber is closed or opened.
A CLV490 bar code scanner identifies a rack

which the robot loads with body parts.
The code reader supplies the data to a cen-
tral computer, for the further working .

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

• Assembling the body in white FOCUS 1
• Insertion of bonnet and tailgate

• Checking the body
FOCUS 2

BODY IN WHITE
FOCUS 3

Body in white, focus 1:
Protecting and controlling turntables.
30
BODY IN WHITE
Protection of hazardous points/hazardous

areas in front of a turntable with C4000
safety light curtain and S3000 safety
scanner. The C4000 stops the rotational
movement of the table if there is an inter-
vention in its protective field. Its height
prevents reaching above. Here, the S3000
serves as point-of-operation guarding, also
capable of protecting a non-rectangular
room. The protective field of the S3000
can be freely programmed within a radius
of 7 m and thus adapted to the spatial
conditions.
On the UE4150 bus node for Profibus, all

safety sensors of a workstation including
emergency stops and signal transducers
can be installed and communicated to,
via the bus. All connected devices can be
analysed and visualised. Simple installati-
on by means of pre-programming and cost-
effective upgrade of systems is possible.
The IVC-2D Industrial Vision Camera mo-

nitors whether the nuts placed on the sheet
part have been correctly positioned and
welded. The working process is continued
only when the camera confirms this. The
data supplied by the IVC is saved, for quali-
ty assurance.
On the turntable, small parts (bolts, lugs)

are welded to a body part. The robot
places a body part in the clamping device
on the turntable. The IQ18 inductive
proximity sensor confirms the presence,
whereupon the clamping device closes and
the table rotates by 180°. The operator
places bolts and lugs into/onto the body
part. The WT12L-2 laser photoelectric
proximity switches indicate their presence.
If all parts are present, the rotating
movement of the table into the robot cell
is started. The robot welds the parts.

Protecting and positioning
in the area of vehicle floor assembly.
32
BODY IN WHITE
Access to the robot cell is protected by a

C4000 Entry/Exit safety light curtain.
This light curtain is used where material is
automatically transported into the hazar-
dous area of a system and, simultaneously,
entry of people must be securely preven-
ted. The C4000 Entry/Exit checks the pat-
tern produced by the skid moving through
the light curtain, and thus can distinguish
between man and material. Additional sen-
sor components such as muting sensors
or swing doors are as unnecessary as addi-
tional inputs or safety relays in the control.
The solution offers great potential savings
in terms of costs for engineering, assembly
and operation.
T400C non-contact safety locks monitor

the swing doors at the infeed/outfeed
station of a robot cell. If a door is opened,
the switch stops the robots’ working
process. T4000C units have non-wearing
solid-state outputs and a feature is simple
installation.
UE10 safety relays support safe automati-

on. They are the link between photoelectric
safety switches and the machine. They
offer the advantages of the classic relay
and modern switching technology. They are
used to link several deactivation areas or
to monitor door switches, two-hand control
circuits and enabling switches.
The IN3000 inductive safety sensor con-

trols, at the foot of a robot, its axis 1
position. This information is passed to the
vehicle control: The start of the automated
guided system (AGS) is permitted only when
the unloading operation is completed.

Protecting, positioning and identifying
in the area of robot cells.
34
BODY IN WHITE
The position of the lifter platform is deter-

mined with a BTF13 wire draw encoder,
which is directly linked to the frequency
converter of the lifter via an SSI interface.
The correct position of the skid on the lifter
is monitored by a photoelectric proximity
switch. The rear photoelectric reflex switch
on the lifter indicates any overtravel to
the correct position; there is also an emer-
gency stop. On the upper level, the first
photoelectric switch indicates that a skid
is positioned in the waiting position. The
second photoelectric switch indicates an
overtravel of the correct position: emer-
gency stop. The light paths of the second
photoelectric reflex switch at the upper
level and the front photoelectric switch on
the lifter as well as the photoelectric switch
at the lower level must be unobscured, for
the lifter to start.
WT12L laser photoelectric proximity swit- The CLV490 barcode scanner identifies the
ches and DS60 distance sensors check a body and ensures the correct allocation of
body for the presence of special recesses, bonnet and tailgate. Thanks to autofocus,
holes, brackets and equipment: optoelec- the reader has an extremely large depth of
tronic quality assurance. focus.
The muting system, consisting of a multiple ensures that the vehicle body is safely
light beam safety device with integrated recognised on the skid as such, that the
M4000 Advanced muting module and M4000 is muted and that the skid can
4 distance sensors (DS60, ObSB [object move into the cell without the system being
between sensor and background]), monitors stopped. If, however, a person enters the
the lock to a portal robot. The special cell, the system is stopped.
arrangement of the DS60 distance sensors

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

• Interior fitting
• Assembly of front and rear screens
• Marriage of body and chassis
with engine
• Assembly of wheels
• Assembly and
final inspection
FOCUS 1

F I N A L A S S E M B LY
FOCUS 2
FOCUS 3

Final assembly, focus 1:
Operator guidance and body identification
in interior fitting.
38
Each storage shelf for small parts is, on its

pick-off side, equipped with a Pick2Light
light grid (PLG). The green job lamp indi-
cates the operator from which bin to take
a component: worker guidance (also called
Pick to Light or Poka-Yoke). If the worker
accidentally reaches into a wrong bin, this
will be shown optically and acoustically.
Here, instead of the light grids (see above),

an LMS sensing laser scanner takes over
the monitoring of the correct picking of
parts, with a pulsed laser beam sweeping
the area to be monitored. According to the
principle of pulse run-time measurement,
the position of the location where the
emitted laser beam is reflected (the opera-
tors hand, in this instance) is determined.
The storage bin co-ordinates are displayed
for the operator, by means of lamps.
The signal lamp above the shelf shows
“red”, and an acoustic signal sounds, if
he or she reaches into a wrong bin.
The CLV450 compact bar code scanner The IT5620 hand-held scanner reads data
identifies a body prior to assembly. The for further equipping the body. The data is
code reader is designed for applications wirelessly transmitted to its ST2020 base
requiring a long reading distance. It also station and, from there, to a central com-
features dynamic focus adjustment. puter.

Protecting access to the assembly cell,
locational and positional control of rear/front screens.
40
The rack station in front of a robot cell is

access-protected by a C4000 safety light
curtain. If the rack is changed or if a per-
son steps through the light curtain, there
will be an enforced interruption of the light
curtain and the robot will stop. However,
the C4000 is muted, for the robot to be
able to continue work in its cell. Simulta-
neously, a second access protection
behind the rack station, consisting of an
S3000 safety laser scanner, is primed
and takes over the safety function. If the
S3000’s light beams are interrupted, too,
then the robot is stopped. C4000 light
curtain and S3000 laser scanner are also
mutually active.
The robot takes a front screen from the

rack, with four WT24 photoelectric proximi-
ty switches taking over the exact positio-
ning of the grabber. This is attained when
all four recognise the black coating at the
edge of the screen. To insert the screen,
the robot then moves to the approximate
position over the body’s front screen cut-
out. It moves its grabbing arm over the
fitting position until the two OD100 dis-
tance sensors capture the body’s edge and
both have determined exactly the same
distance. Thus, the X, Y and Z co-ordinates
for the position of the robot arm in relation
to the body have been determined. They
are saved. The screen is accurately inser-
ted.
Here, a WF100 fork sensor takes over the

job of the two OD100 distance sensors
(see position 1). With it, to determine the
position, two dedicated points in the body’s
screen cut-out are approached, and thus
the X, Y and Z co-ordinates for the position
of the robot arm in relation to the body are
determined.
The entry into the assembly cell is protec- The skid with the body can thus pass with-
ted by two S3000 proximity laser scanners. out triggering a signal. Swing doors are
Here, two devices were used to avoid not needed since the protective fields of
shadows and thus monitoring gaps next to the S3000 units are always active on the
the body and the transport track. The two sides. If a person interrupts one of the
protection fields are adjusted to the body protective fields, the transport track and
profile in steps, via IQ40 inductive proximity the robot movements are stopped.
sensors arranged along the transport track.

Positional control and collision protection on scissor lifts,
backup control and identification for the supply of wheels.
42
On the suspended conveyor, IQ40 induc-

tive proximity sensors over the runner
serve to position the scissor lifts for cor-
rectly positioning the vehicles for wheel
assembly. DS60 distance sensors ensure
the correct distance of the suspended
vehicles with scissor lifts. They monitor
their relative distance: collision protection.
The devices have two switching points
which can be allocated at certain distan-
ces. When reaching switching point 1,
the suspended vehicle switches to creep
mode, with a stop at switching point 2.
The IQ40 inductive proximity sensor on
the scissor lift switches if the scissors are
closed, and thus permits e.g. the exit from
the assembly cell.
The ICR890 camera system identifies tyres

prior to storage or prior to assembly onto
wheels. The bar code to be read is attached
to the tyre bead and can no longer be seen
after pulling onto the wheel. The identifi-
cation ensures that the right tyre is taken
to the right storage location or allocated
to a particular wheel. The information read
can be saved on a central computer, for
quality assurance.
WLR1 photoelectric reflex switches con-

trol the supply of wheels to the assembly
station. The devices are conceived for
so-called “backup conveyors”. They are
equipped with solenoid valves. The trans-
port track is divided into segments, at the
end of which there is always one WLR1
mounted with a reflector. The internal logic
of the devices ensures a controlled flow of
materials, for the onward transport of the
wheels to be started or stopped at defined
segments.
The OPS290 omnidirectional bar code rea- code scanners with swivelling mirrors and
ding system identifies wheels prior to auto- an OTC Omni Tracking Controller. The two
matic assembly and thus ensures that the reading lines cross and move over the
correct wheels with the correct tyres are object to be scanned, to thus be able to
fitted to the vehicle. The system consists of reliably recognise codings irrespective of
two CLV490 autofocus bar their positions.

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

• Assembly of the cylinder head F
• Assembly of the engine block

• Marriage of engine block and cylinder head
• Assembly of accessories
FOCUS 3

ENGINE AND GE ARBOX PRODUCTION
OCUS 1
FOCUS 2

Engine and gearbox production, focus 1:
Protecting of processing machines and automatic
loading stations. Controlling and monitoring of grabbers.
46
The loading station before the machining

line is access-protected from people using
C4000 safety light curtains and M4000
multiple light beam safety device. Both
safety devices are switched as a “lock”.
If an empty rack is brought into the station
or if a filled one is collected, the C4000
light curtain is interrupted, the M4000
multiple light beam safety device then
takes over the protective function: the por-
tal robot can continue to work. It is stop-
ped only if the M4000 is interrupted too.
After the rack change, the C4000 safety
light curtain again takes over the access
protection. Now the rack can interrupt the
M4000 multiple light beam safety device
without the gantry loader being switched
off. The safety devices can be switched
via a safety PLC or a UE safety interface.
Two IQ40 inductive proximity sensors indi-

cate that a filled rack is standing in the
collection station. The CLV490 bar code
scanner passes the data of the machined
cylinder heads to a central computer.
The IM18 inductive proximity sensor in- The i16 safety switch safeguards the sliding The ATM absolute multiturn encoder re-
dicates the presence of the workpiece to door on an encapsulated processing ma- ports the horizontal position of the lifting
the control unit of the processing machine chine. The machine is stopped instantly mechanism to the control system. It can
and releases it for machining. The IM30 when the door is opened. Machines with be integrated into the control system, via
proximity sensor (top centre) signals the long stopping times are protected by different interfaces (SSI, RS422, Profibus,
opening of the clamp device for the auto- safety switches with locking devices, e.g. DeviceNet, CANopen).
matic removal of the cylinder head. i100 Lock. The safety switch allows the
sliding door to be opened only when the
machine has stopped.

Hazardous point protection of assembly robots. Lubricant
control and component identification for quality assurance.
48
Hazardous point protection on a “robot sta-

tion” (handling robot) with C4000 safety light
curtains. It is possible to step behind the ver-
tically arranged safety light curtain, as pre-
sently fitted. To protect the operator from
this, another short C4000 is mounted below
the vertically attached light curtain. Both
safety light curtains are serially connected
with one another (cascading): The vertically
arranged C4000 serves as host, the horizon-
tally arranged one as guest. Any intervention
in the protective fields stops the handling
robot. The UE470 safety controller deals
with the machine’s entire safety technology.
Emergency stop and safety switches, light
grids as well as the signals of the machine
for controlling the bottom/top dead centre
process are directly connected to the UE470.
Various programs, required for different
operations, are saved in the UE470. These
can be called via a program change-over
switch. It is also used to select the process-
dependent safety functions. Using the UE470 Following assembly, the cylinder head is
negates the wiring of several safety relays sprayed with lubricant. It provides the first
in the control cabinet. Costs for installation, supply when the engine is started. The
assembly as well as commissioning are LUT3 luminescence scanner checks the
reduced. presence. It emits ultraviolet light, which
converts the luminophors in the lubricant
to visible light, which is received by the
LUT3. The onward transport of the cylinder
head is stopped if no lubrication film is
The IVC-2D Industrial Vision Camera checks present.
the presence of lubricant in the groove of
the bearing shell. The lubricant is supplied
to the bearings when the engine is first
started. If the IVC communicates that there
is no lubricant, this will be indicated.
The ICR850 code reader reads the two-

dimensional code on the camshaft and thus
checks whether the correct camshaft is
fitted. It passes the information to a central
computer, for quality assurance.
The OD100 distance sensor checks the

correct camshaft position, prior to placing
the drive chain.
The data of the fully assembled cylinder

head is transmitted to the quality manage-
ment system, via an IT5620 hand-held
scanner with wireless data transmission
(ST2020).

Entry protection of robot cells.
Positioning and indicating of workpiece carriers.
50
The C4000 safety light curtain protects the

material lock to the assembly cell. Four
IQ40 inductive proximity sensors act as
muting sensors. Their special arrangement
ensures that the workpiece carrier with
its engine is admitted without interrupting
the robot’s working process. If, however,
a person enters the cell, he or she will be
detected by the C4000 safety light curtain
and the system stopped.
A cylinder head enters the assembly cell on

its workpiece carrier. The transfer system
is controlled via three IQ40 inductive proxi-
mity sensors which indicate the position of
the workpiece carrier: the workpiece carrier
is stopped at the handover station.
The UC12 ultrasonic proximity sensor in-

dicates the presence of a cylinder head.
The robot grabs it and places it on the
engine block. The four binary sensors,
the photoelectric proximity switch and the
three proximity sensors (see above) are
cost-effectively networked, via an AS inter-
face field module, with the first bus level.
(Actuator Sensor Interface = lowest field
bus level).

Network technology:
Fieldbus integration, platform- and system-neutral.
FOCUS 1
52
NE T WORK TECHNOLOGY
Open for all bus systems.
As a “one-stop supplier”, SICK takes a neutral stance regarding the subject

of fieldbus integration. SICK sensors offer connectivity options for almost
all known fieldbus systems: PROFIBUS and PROFIsafe, AS-Interface and AS-
Interface Safety at Work, DeviceNet and DeviceNet Safety as well as Ethernet.
Beyond the mere connection, SICK also offers complete automation. For the
AS-Interface and DeviceNet system worlds, standalone and configurable con-
trols are available in addition to the sensor integration. This enables solutions
to automation tasks and the creation of flexible and cost-effective “monolithic”
complete solutions.
The user determines which integration will be implemented. In each case, they
can use the benefits of fieldbus technology, e.g. reduced hardware, less system
FOCUS 2
planning through the modular fieldbus design or optimisation of machine main-
tenance by reducing the choice/variety of units, remote maintenance, diagno-
stics and parameter download.

SICK sensors from the Divisions of The available integration options in
Industrial Sensors, Industrial Safety control engineering, based on world-
Systems and Auto Ident can be used wide standards, make each and every
on almost all system platforms. solution a longterm future investment.
DME5000 W12-3 photo- W27-3 photo- IM18 inductive MLG automation

distance sensor electric switch electric switch proximity sensor light grid
IVC-2D Industrial ATM60/90 absolute

Vision Camera multiturn encoder
I/O link
Connecting module • PROFIBUS, PROFIsafe

for CDM400
bar code scanner • PROFINET
• DeviceNet, DeviceNet Safety
• Ethernet, Ethernet/IP
• AS-i, AS-i Safety at Work
• SICK CAN Scanner-Network
Base station
CLV420 CLX490
bar code scanner omnidirectional bar
code reading system
Connecting module OPS400

for CDB400 OMNI-Portal Scanner
bar code scanner
IT5620
hand-held scanner
54
NE T WORK TECHNOLOGY
C4000 M4000
safety light curtain multiple light
W12-2 photo- W27-2 photo- beam safety
electric switch electric switch device Safety positioning
switch
S3000 safety
Safety switch laser scanner
AS-i fieldbus module AS-i Safety at Work PROFIsafe safety DeviceNet

Slave UE4200 bus module UE4100 safety bus module
UE4400
SNC Safety Network

Controller
FDT/DTM Technology OPC Server

• Standardised “Style Guide”: • Status and diagnostics directly
Different device tools can be ope- to the HMI (Human Machine Inter-
rated using the same philosophy. face) and via company network
• Central data storage: The configu- • Remote maintenance from every
ration data of the individual device site, and into the protective field
manufacturers, the DMTs (Device • Information management: confi-
Type Manager), are stored centrally guration backup stored centrally
in the FDT (Field Device Tool). • With a few mouse clicks, Active-X
• Uniform access point: Only the FDT enables a representation of protec-
makes the connection to the device tive fields in the OPC Client.
via the field level.

RANGE OF EXPERTISE
INDUSTRIAL SENSORS INDUSTRIAL SAFETY AUTO IDENT A N A LY ZE R S A N D PRO C E S S

SYSTEMS I N S T RU M E N TAT I O N
Our complete range of sensors Comprehensive safeguarding of Whether the tasks involve System control, maintaining
provides answers to suit any both personnel and machinery! identification, handling, classifi- setpoints, optimising process
application in the field of auto- As specialists in Sensor Techno- cation or volume measurement, control and monitoring the flow
mation. Even under rugged logy, SICK develops and manu- innovative Auto Ident systems of materials – the instruments
ambient conditions objects are factures pioneering products for and laser measuring systems and services for Analysis and
reliably detected, counted and providing protection in hazardous function extremely reliably, even Process Measurement, supplied
positioned in respect of their zones, dangerous locations and under rapid cycle times. They by SICK MAIHAK, are setting
form, location and surface for safeguarding access points. conform to the latest Standards the standards for these appli-
finish, as well as their distances By providing services, which en- and can be simply and speedily cations in terms of Technology
established with pin-point accu- compass all aspects of machine integrated in all industrial en- and Quality.
racy. safety and security, SICK is vironments and external appli-
setting new standards in Safety cations.
Technology.
Subject to change without notice · 00 WB int25
8009329/11-05 · MRH/FD · Printed in Germany (12-05)
Worldwide present with Australia Schweiz

subsidiaries in the following Please find the detailed
Belgium/Luxembourg Singapore
countries: addresses and more represen-
Brasil Republic of Korea tatives and agencies in all
major industrial nations at
Ceská Republika Republika Slovenija
www.sick.com
China Suomi
Danmark Sverige
Deutschland Taiwan
España Türkiye
France USA/Canada/México
Great Britain
India
Italia
Japan
Nederlands
Norge
Österreich
Polska
Russia
SICK AG | Waldkirch | Germany | www.sick.com

Sensor Solutions For The Automotive Industry

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INDUSTRY GUIDE

Process Optimisation in Every Detail

Leading-edge sensor technology

The optimisation of operations in automotive production is a

As an independent and world-leading developer and manufacturer

Complete Sensor Supplier

2 AUTOMOTIVE INDUSTRY | SICK

On the following pages, you will find an

Together, we can discover your optimi-

Press Room Sensors 18

SICK | AUTOMOTIVE INDUSTRY 3

Because the industry knows no limits

In the automotive industry, it’s the global perspective

In addition to distribution and service, SICK is geared to

As an innovative complete sensor supplier with worldwide

Benefit from SICK’s worldwide presence. Always and

4 AUTOMOTIVE INDUSTRY | SICK

Europe America Asia

“Sensor Intelligence”, integrated

This integration is perfectly illustrated for the automotive

This, of course, is of particular benefit to you. With “Sensor

Combine safety and control to achieve complete inte-

Encoders, ultrasonic sensors, inductive, capacitive

6 AUTOMOTIVE INDUSTRY | SICK

INDUSTRIAL SAFET Y SYSTEMS AUTO IDENT

SICK | AUTOMOTIVE INDUSTRY 7

Technology does not evolve by itself. Progress only comes

SICK has always invested more than most in research and

Something which in 1950 began with the first practical

8 AUTOMOTIVE INDUSTRY | SICK

SICK | AUTOMOTIVE INDUSTRY 9

From planning and operation

The particular issue of safety is certainly not completed

With the “International Service Solutions” from SICK you

Use the “International Service Solutions” for more safety

TRAINING & CONTINUOUS T H E O N LY A C C R E D I T E D

10 AUTOMOTIVE INDUSTRY | SICK

During the whole machine life cycle

SICK | AUTOMOTIVE INDUSTRY 11

The Online Portal is a must where efficiency and fast pro-

Sensor planning online – in the SICK Partner Portal

The big online product catalogue:

12 AUTOMOTIVE INDUSTRY | SICK

• Your work becomes even more efficient online

Price and availability query:

SICK | AUTOMOTIVE INDUSTRY 13

Selected solutions to problems

THE 4 PROCESS STEPS – AN OVERVIEW 16

Focus 1: Directing, controlling and protecting stacker cranes

Focus 1: Protecting and controlling turntables

Focus 1: Work guidance and body identification in interior fitting

Focus 1: Protecting of processing machines and automatic loading stations

14 AUTOMOTIVE INDUSTRY | SICK

Discover, step by step, how SICK

We have illustrated the entire

SICK support you in this.

The following applications only show the solution of

SICK | AUTOMOTIVE INDUSTRY 15

SICK offers sensor solutions

16 AUTOMOTIVE INDUSTRY | SICK

4. ENGINE AND GEAR-

SICK | AUTOMOTIVE INDUSTRY 17