Safety technology for shuttles and overhead conveyors in intralogistics
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Safety is the highest priority in automated material transport. To ensure safe material and goods flows in the Intralogistik To ensure this, autonomously operating systems rely on secure absolute positioning and secure speed detection. Conventional technologies can only achieve this task with great effort and considerable complexity. Pepperl + Fuchs offers a significantly simplified security solution
Content
- Autonomous systems in intralogistics
- Color redundancy for shuttles and skids
- Code rails for large equipment in material flow and logistics processes
- Frequently asked questions
The safe execution and optimization of processes in intralogistics are crucial for the flow of goods and materials. In order to reduce the effort required to safely record absolute positioning and speed detection of autonomously operating devices and systems, Pepperl + Fuchs is presenting a new development: With the evaluation unit PUSwith the Sensors Safe PXV or WCS the company offers a significantly simplified solution. With minimal integration effort, this solution is designed for safety functions in accordance with SIL 3 and PL e.
Autonomous systems in intralogistics
Core tasks of intralogistics are increasingly being carried out by autonomous systems Overhead conveyors, shuttles or crane systems with a high degree of automation ensure rapid material transport. People in the area must be reliably protected from collisions.
At the same time, of course, property damage must also be avoided. Machinery Directive (EU Directive 2006/42/EC) specifies exactly which measures must be observed. Similar rules also apply in other regions of the world. A fundamental factor here is the secure absolute position.
Security requires redundancy or a comparison between various sensors and technologies. This is usually achieved through multiple design. This increases costs and complexity accordingly. Pepperl+Fuchs combines the Safe Evaluation Unit PUS with a proven positioning system of the Safe PXV or WCS types and thus pursues a different approach. Both variants are certified according to EC 61508 for SIL 3 and according to EN 13849 for PL e.
Color redundancy for shuttles and skids
The Safe PXV system is typically used for the safe positioning of shelf shuttles in warehouse logistics or in electric monorail systems. These are often used in the assembly halls of Automotive industry Efficient organization and precise planning of the material flow are crucial here to ensure smooth operations and identify weak points in warehousing.
Combined with the Evaluation unit PUS The safety system outputs position and speed values and thus provides the basis for the safety functions: safe position monitoring (SLP) and safely limited speed (SLS). In the case of rack shuttles, this makes it possible for human personnel to carry out maintenance work or other interventions in individual aisles without first having to shut down the entire system.
The Safe PXV system achieves redundant signaling with just one sensor. This is done based on a band with large three-colour Data matrix codes. These are illuminated by red and blue LED flashes in a safety-rated sequence. The Camera This means that only a portion of the colored codes are captured per flash.
Independent plausibility check
A secure algorithm compares the signals and thus ensures an independent plausibility check. If the image information and the recorded position do not match, the system reports a malfunction. The safety circuit is triggered. The LED rings are controlled by the evaluation unit. The device automatically checks whether the camera software is working correctly.
The safety system is very robust. To determine the position on the X-axis to an accuracy of 0,2 mm, only a data matrix code is needed. This also works if there are damaged sections of belt on a section up to 10 kmThe safe evaluation unit PUS-F161-B carries out the evaluation.
This processes and evaluates the data on two channels, calculates the safe position value from which it can derive a safe speed value. At the same time, it transmits diagnostic data from the connected sensor to the fieldbus. By comparing the values of its two separate channels, the redundancy requirements of category 4 according to EN ISO 13849-1 are met. Plug is sufficient for the connection to the channels.
Code rails for large equipment in material flow and logistics processes
In particularly harsh conditions, the Path coding system WCS provides the data for absolute positioning. It has proven itself in the positioning of cranes, both in large gantry cranes that move containers in the port and in indoor crane systems with trolleys. The large machines require particularly robust sensors that are climate-resistant and not affected by strong mechanical influences.
The WCS uses a 70 mm wide, vertically aligned code rail made of Stainless Steel with punched recesses as a measurement basis. These gaps can practically not get dirty. Several photoelectric sensors surround the rail as a U-shaped reading head. They detect the rail after the Photocells-Principle.
The sensor's design excludes the influence of extraneous light. While it moves with the mobile element of the transport system at a speed of up to 12,5 m/s, it detects every 0,8 mm per ms Real time a new absolute position value.
Unshakeable even in harsh conditions
Neither smoke, dust, nor extreme temperatures and weather influences the detection. The code rail can be used on slopes and curves as well as with interruptions and switches at a maximum Track length of 314,5 m be installed.
For outdoor use, the WCS Outdoor device version is available. It is equipped with an additional transparent, dust and moisture-proof Housing even more robust than the normal version. In addition, the IP69 version can withstand salt water, aggressive substances and high-pressure cleaning.
The safe, redundant design of the WCS system requires two reading heads mechanically connected to form a unit. Each reading head has its own orientation with a different counting direction, thus ensuring separate signaling.
Here, too, the company's secure evaluation unit PUS-F161-B*-WCS is responsible for evaluating the sensor data. These are transmitted to the safe steering The systems are pre-certified and pre-configured. This makes commissioning quick and easy.
Frequently asked questions
What does intralogistics include?
Intralogistics includes all processes that internal material and goods flow control. The term refers to the organization, control and optimization of storage, transport and order picking within a company. Intralogistics plays a central role in German mechanical and plant engineering, as it has a significant impact on efficiency and productivity in production. Intralogistics includes systems such as conveyor systems, storage technology, sorting and packaging systems, and the associated software. These components work together to optimize the flow of materials within production facilities and warehouses.
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Markus Karch is Global Product Manager, Product Management Innovation Unit Industrial Vision Components, Factory Automation, at Pepperl+Fuchs SE, Mannheim.