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 & parameterization

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

4 Installation & 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 & acceptance

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

Safety solutions – examples

Safeguarding of robot/AGV transfer stations

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, SIL 2 in accordance with IEC 61508
  • 2-channel safety output

Access monitoring at material transfer stations

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
  • Safe and reliable even under demanding conditions, e.g. with fully loaded or empty pallets
  • 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 e in acc. with EN ISO 13849-1, SIL 3 in acc. with IEC 61508
  • 2-channel safety output, 2 signal outputs

Access guarding on multi-track transport systems

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 d in accordance with EN ISO 13849-1, SIL 2 in accordance with IEC 61508
  • 2-channel safety output

Area guarding at transverse side-tracking skate

Requirement: 

The transportation path of the transverse side-tracking skate 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 side-tracking skate. 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 side-tracking skate 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 acc. with EN ISO 13849-1, SIL 2 in acc. with IEC 61508
  • 2-channel safety output