Safety Solutions

Efficient material flow and maximum safety

The increasing automation of processes places growing demands on safety concepts. Classic concepts such as muting are often pushed to their limits here, e.g. at transfer stations and material locks. Our innovative safety solutions guarantee gapless safety, efficient material flow and high availability of your system, even with automatic processes.

Use our experience and our know-how

Innovative ideas are based on experience and know-how. For more than 30 years, we have been supporting safety-related applications in different industries by offering a broad range of products. Our safety experts have comprehensive knowledge of the latest norms and standards and extensive experience in designing safety concepts. This allows us to develop efficient safety solutions for use in automated environments.

  • Global network of certified experts for the creation of safety concepts and the validation of the solutions on-site
  • In-house Solutions Engineering Center
  • Development and design according to the V-model in accordance with EN ISO 13849-1
  • Extensive selection of in-house safety products

Your partner for efficient safety solutions

From the gathering of the requirements to the safety acceptance, you are accompanied by our professional project teams. They make sure that the safety solution meets your requirements and ensure that the project runs smoothly.

 

Tailored to your needs

Our solutions are based on qualified safety concepts which, if necessary, can also be extended or created new. Every solution is individually tailored to your system layout and includes

  • All necessary hardware and software components
  • Engineering services, such as configuration according to project requirements
  • Start-up support
  • Validation of the safety function
  • Full documentation

The path to your solution

1. Gather requirements

  • Examine layout and danger zones, clarify processes
  • Check risk assessment, define protective goals
  • Clarify timing

2. Selection of the safety concept

  • Evaluation of the requirements by our safety experts
  • Selection of the appropriate safety concept and the required components

3. Configuration and parameterization

  • Configuration of the safety system
  • Programming and parameterization according to requirements
  • Project-specific documentation

4. Installation and commissioning

  • Provision of the mounting and installation instructions
  • Mounting and installation of the system components
  • Support during commissioning and the integration in the control

5. Safety inspection and acceptance

  • Validation of the safety function
  • Initial inspection of the safety devices
  • Creation of the acceptance documentation

Safety solutions – examples

Requirement
The danger zone of the robot and the working range of the transfer station should be safeguarded against entry by persons during the entire process. The vehicle should be able to enter and exit the work area fully automatically.

Solution
The entire area of the transfer station is safeguarded with safety laser scanners. As the vehicle passes through, the protective field dynamically adapts to the position of the vehicle by blanking the outline of the AGV from the protective field.

Advantages for you at a glance

Monitoring for the entry and presence of persons
Gapless safety during the entire cycle
No restrictions during part transfer, e.g., for parts that protrude at the front or side
Autonomous system, simple safety integration

System components and safety parameters

  • Safety sensors: RSL 400 laser scanner
  • System controls: Siemens SIMATIC S7
  • Leuze safety program
  • PL d in accordance with EN ISO 13849-1, SILCL 2 in accordance with IEC 62061
  • 2-channel safety output

Requirement
The robot cell is fed automatically. The material is loaded onto the conveyor line, e.g. using a forklift truck, and then transported into the cell. Access to the cell must be safeguarded. To guarantee optimum capacity utilization of the robot cell, the safety concept must also allow uninterrupted operation of the cell during loading.

Solution
The loading area of the conveyor line is guarded at both the entry and exit side by multiple light beam safety devices. The area between the photoelectric sensors is monitored for the presence of persons by means of safety radar sensors.

Advantages for you at a glance

  • Higher capacity utilization of the system through interruption‑free operation of the robot cell, even during loading
  • Infeed of transported goods of any shape or size thanks to an optimized safety concept
  • Access guarding with dynamic format adaptation
  • Supports automatic starting of the conveyor line to improve efficiency and safety
  • No operator action required
  • No visual monitoring of the danger zone necessary 

Operating principle

After the safety sensor on the feed side has been interrupted and released again, the airlock area is checked. Radar sensors monitor this area for the presence of people. The system only releases the safety sensor on the outfeed side if no person has been detected in the airlock area and the conveyed goods can be transported into the cell. The system monitors whether the processes are correct in terms of safety. The system provides the necessary release signals for the implementation of automated loading processes.

System components and safety parameters

  • Safety sensors: MLD 500 multiple light beam safety devices, LBK safety radar sensors with controller
  • System control: MSI 400 safety control
  • Leuze safety program
  • PL d in accordance with EN ISO 13849-1, SILCL 2 in accordance with IEC 62061
  • 2-channel safety output, 2 signal outputs

Requirement
Pallets are output on individual tracks that are fed via a cross conveyor. The cross conveyor and the area located behind it are to be safeguarded against entry by persons. The protection should only release the track on which the pallet is output.

Solution
Access guarding takes place via two vertically oriented safety laser scanners. From the system control, the safety system receives the information about the track onto which the pallet is output and adapts the protective field for the passage of the pallet accordingly. The entire process is monitored for safety.

Advantages for you at a glance

  • Continuous monitoring of the entire transfer area for up to 10 tracks and width of up to 9 m
  • Gapless safety during the transport cycles
  • High reliability and availability
  • Optimum protection against manipulation
  • No additional trigger sensors necessary
  • Easily retrofittable

System components and safety parameters

  • Safety sensors: RSL 400 laser scanner
  • System control: Leuze MSI 400
  • Leuze safety program
  • PL e in accordance with EN ISO 13849-1, SILCL 2 in accordance with IEC 62061
  • 2-channel safety output

Requirement
The transportation path of the transverse transfer car is to be monitored for the presence of persons by using safety laser scanners. To ensure optimum utilization of the building's surface area, the skate is to move into the vicinity of the wall. For this purpose, the protective field of the safety laser scanner must gradually be reduced as the skate approaches the wall.

Solution
An area protection system with a safety laser scanner in each direction of travel is installed on the transverse transfer car. The autonomous system detects when the skate is approaching the adjacent wall, and automatically reduces the size of the protective field of the safety laser scanner.

Advantages for you at a glance

  • Improvement of the safety concept across the entire travel range of the transfer car without any reduction in system performance
  • The autonomous systems can each be easily integrated into the system control via a two-channel safety output
  • Easily retrofittable, minimal mechanical installation requirements
  • Also for the operation of 2 skates in one aisle

System components and safety parameters

Area protection system using the following in each direction of travel

  • Safety sensor: RSL 400 safety laser scanner
  • System control: MSI 400 safety control
  • Leuze safety program
  • PL c in accordance with EN ISO 13849-1, SILCL 1 in accordance with IEC 62061
  • 2-channel safety output

Requirement
Pallets are automatically fed in and out by a conveyor belt. Access guarding should permit the transport of goods with changing width as well as with different positioning on the pallet and simultaneously prevent persons from running alongside.

Solution
Access guarding takes place via two vertically oriented safety laser scanners. Measuring sensors determine the width and position of the goods and send this information to the Leuze safety system. This appropriately adapts the protective field for passage of the goods.

Advantages for you at a glance

  • Continuous monitoring of the entire access area
  • Gapless safety during the transport cycles
  • High reliability and availability
  • Low service costs
  • Optimum protection against manipulation
  • Easily retrofittable

Operating principle

Two safety laser scanners produce a vertical protective field. Installed in front of the protective field on both sides next to the conveyor line are optical distance sensors that detect the width of the goods and their position on the conveyor line. The safety system uses this information to release an appropriate window in the protective field through which the goods can be transported interruption-free. Access remains safeguarded alongside the goods. After the goods have passed through the opened protective field window, the protective field is again reset to its original, closed state. The entire process is monitored for safety.

System components and safety parameters

  • Safety sensors: RSL 400 safety laser scanner
  • Measuring sensors: optical distance sensors
  • System control: Siemens SIMATIC S7
  • Leuze safety program
  • PL d in accordance with EN ISO 13849-1, SILCL 2 in accordance with IEC 61508
  • 2-channel safety output

Requirement
The transfer car crosses the travel path at regular intervals. During the entire movement process, the relevant part of the travel path is to be safeguarded against the entry of persons. The transfer car should, however, be able to pass through the monitored area fully automatically.

Solution
The relevant part of the travel path is safeguarded by safety laser scanners. These use their protective fields to detect the entry and presence of persons. During the travel process, the contour of the skate is dynamically blanked out of the protective fields. The entire area thereby remains optimally protected at all times.

Advantages for you at a glance

  • Monitoring for the entry and presence of persons
  • Gapless safety during the entire process
  • No restrictions during part transfer – even parts that protrude are possible
  • Autonomous system with simple integration in the safety circuit of the primary control
     

Operating principle

With their protective fields, the safety laser scanners protect the part of the travel path in which the transfer car moves. They simultaneously detect the presence of persons and the position of the skate in the monitored area. During travel, the safety system uses this information to blank out the contour of the skate by changing over the protective fields from the monitored area. The monitored area is thereby fully protected and the safety level is maintained during the entire process.

System components and safety parameters

  • Safety sensors: RSL 400 safety laser scanner
  • System control: Siemens SIMATIC S7
  • Leuze safety program
  • PL d in accordance with EN ISO 13849-1, SILCL 2 in accordance with IEC 62061
  • 2-channel safety output

Requirement
Access guarding of the pallet magazine should prevent the entry of persons and simultaneously permit the entry of pallets by a forklift truck. After the forklift truck has again left the transfer area, restart should occur automatically to minimize the interruption of the work process.

Solution
The access area is protected by a safety light curtain. In addition, induction loops are embedded in the floor in the areas in front of and behind the safety sensor. The safety system can thereby distinguish between forklift truck and persons.

Advantages for you at a glance

  • Optimum system utilization through automatic restart of the machine without manual operator interventions
  • High reliability and availability
  • Low service costs
  • Optimum protection against manipulation
  • Simple integration in the safety circuit of the primary control

Operating principle

Upon triggering of the safety light curtain, the work process of the pallet magazine is interrupted – regardless of whether a person or a forklift truck interrupted the protective field. If, however, the presence of a forklift truck is detected by the induction loops installed in the floor and if this then correctly executes the specified process sequence, the safety system initiates the automatic restart of the work process.

System components and safety parameters

  • Safety sensor: MLC 500 safety light curtain, with device columns for floor mounting
  • Induction-loop set with evaluation unit
  • System control: MSI 400 safety control
  • Leuze safety program
  • PL d in accordance with EN ISO 13849-1, SILCL 2 in accordance with IEC 62061
  • 2-channel safety output