PRESS RELEASE
Object detection and personal safety from the corner
By Wolfram Tanner, Product Manager Light Beam Systems in the Industrial
Safety Systems Division, SICK AG, Waldkirch
Two tasks – two sensors – one technology
An innovative camera system, integrated into a rectangular shaped housing, results in a “vision sensor”
technology platform which provides quick solutions for two different tasks: The Safety Camera Sensor for
safeguarding semi-automated work places and the Automation Camera Sensor for improving processes
of industrial automation.
Independent of the different tasks, the camera sensor always works together with a flexible reflective
tape. This tape defines the protective field of the safety system respectively the switching area of the
automation system.
The different paint finishes of the two devices points to their differing characteristics: The automation
camera sensor remains in a classic blue while the safety camera sensor is in the signal color yellow, as is
standard in safety technology.
Camera chip as the common core technology
The technical basis of both devices is an image processing system consisting of a powerful camera chip
and intelligent programming. The sensor's sender, receiver, and electronics are integrated into a single
housing. A special reflector strip mounted in the sensor's field of vision defines the protective field. The
sensor emits infrared light which is sent back by the reflector. The resulting image is displayed on the
receiver chip and evaluated within just a few milliseconds. This means that any changes in the protective
field, such as entry with hands into hazardous points or an overhanging pallet on a conveyor system, can
be detected extremely quickly. A response time of 20 ms is guaranteed.
Easy installation without alignment
The self-adhesive reflector strip is usually attached on a profile frame or on a machine wall in order to
define the protective field. The camera sensor is placed opposite so that the reflector strip is in its field of
vision. One press on the teach button and the camera automatically searches for its reflector. Lengthy
fine-tuning is not necessary. The optical aperture angle measures approximately 110° lengthwise.
Sideways, the camera sensor is able to "squint" about 10° to the left and right. With this wide field of view,
the camera sensor can be positioned in variable locations and still sees the entire protective field. This
provides a number of options for positioning the device and the reflector at the best possible place in the
machine. Consequently, the valuable camera sensor can be protected against mechanical damage, for
example, or even just discreetly integrated into a machine design.
Active from the corner, without blind zone
The triangular housing design allows the perfect integration of the camera sensor into the corners of
profile frames. From there, the sensor faces the reflector strip opposite, which specifies the protective
field. The strip can be precisely cut to the required length. Dead zones or device overhangs, as
sometimes unavoidable for light curtains, are a thing of the past. The resulting protective field ends
precisely there where the reflector ends.
Flexible protective field configuration
The reflector strip can also follow unusual contours. This enables curves or steps to be integrated into the
protective field. The protective field no longer has to be a square. This means that for example annoying
cable channels can be easily bypassed. Also round shapes like the edge of a rotary table can be
achieved.
Permanent reliability
The camera sensor and the reflector strip together form a reliable unit. The strip's adhesion is so strong
that it will not detach even under severe industrial conditions. Another quality feature: The surface of the
reflector strip is extremely resistant to scraping movements. This has been proven by endurance tests in
which, for example, a loaded crate was shoved over the reflector 10,000 times. If anyhow scratches do
occur on the reflector strip, the camera system is intelligent enough to ignore these and to distinguish
between scratches and a human body part or an object to be detected.
Platform concept generates unique sensor solutions
With its innovative camera technology a smart, powerful and easy-to-use alternative to light curtains has
been created. It is useful for a variety of automation and safety technology applications.
The yellow Safety Camera Sensor has an eye on safety
The safety camera system is suitable for hand protection in applications with a required Performance
Level “d” or lower. It allows the protection of work windows for example on assembly and handling
machines or on test stations. Also, it can protect industrial robot movements. Basically, all kind of semiautomated work stations, used routinely or sporadically, can be reliably protected without barriers, with
this sensor. In many cases this relates to applications for which category 3 and Performance Level (PL)
"d" according to ISO 13849-1, or SIL 2 according to IEC 61508 is required. Due to a lack of alternatives,
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light curtains from the higher safety levels (Cat 4, PL "e", SIL 3) previously had to be used for such
applications. The safety camera sensor with the appropriate safety design and the innovative single
housing concept is a more favorable solution in this case.
It can protect windows up to a size of 1.50 m x 1.50 m. If two devices are synchronized and used
simultaneously, the protective field size can even be doubled to 3.00 m x 1.50 m. An ergonomically
optimized, barrier-free work place can also be designed with two V300 cameras installed across in the
corners. Both camera systems synchronize automatically.
The blue Automation Camera Sensor directs its gaze to automation
Demand for 2D sensors is widespread in the area of industrial automation. Intralogistics alone provides a
multitude of application possibilities. For example, when transferring palettes from one unit to another, it
must be ensured that the clearance between the approaching and the fixed unit is free from top to bottom.
The load must not shift, and the palette must not become jammed such that it can no longer be removed
during the transfer of the load from one side to another. The clearance must be reliably monitored in order
to prevent a collision and subsequent damage. The precision requirements are in the range of 15 mm.
In comparison with the safety camera system, the “non-safe” automation camera makes it possible to
secure much larger areas. The maximum possible field dimensions are 2.00 m x 2.00 m. Before the
introduction of the automation camera sensor, this type of clearance monitoring was previously only
possible with conventional light curtains. But it was not always possible to install the right light curtain
sender and receiver lengths for the application.
Innovative for the future
One innovative vision technology, integrated in two types of camera sensors, results in two product
families with fundamentally identical technologies but for different fields of applications. With this
innovative and unique sensor solution an alternative for common light curtains is created. The integration
of sender and receiver into one device opens up new opportunities for customers in the design of their
machines. A new trend for the future is set.
SICK is one of the world's leading manufacturers of sensors and sensor solutions for industrial
applications. Founded in 1946 by Dr.-Ing. e. h. Erwin Sick, the company is headquartered in the German
town of Waldkirch, in the Breisgau region near the city of Freiburg. It is a technology and market leader,
maintaining a global presence with more than 50 subsidiaries and equity investments as well as
numerous representative offices. In the 2014 fiscal year, SICK had around 7,000 employees worldwide
and generated Group revenues of €1,099.8 million.
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