SafetyEYE® Monitors KUKA’s RoboTeam

KUKA RoboTeam in a jigless cell

A team of robots comprising two process robots and two handling robots welded the car door together in one work stage. Two jigless grippers combined to perform the geometric functions. The two gripper half shells were positioned by cooperating robots. The jigless bodyshop, therefore, is an innovative plant technology, which implements the very latest robot functionalities without the classic holding and clamping technology. The cycle time can be minimized through direct "geometric coupling". Autonomous control systems provide a high degree of flexibility. Cooperation between the team robots allows for highly flexible component positioning.

SafetyEYE® protects workers in the infeed areas
These days robots almost always work behind safety fences, screened from the application operator. New safety concepts such as SafetyEYE® help to do away with the fences and barriers that come between worker and robot. From above, SafetyEYE® simultaneously protects workers in both infeed areas independently. The operator enters the transfer area, where he is detected visually. This is safely recorded and the data is transmitted to the safety-related robot control system. The aim is to avoid a collision; this can be guaranteed by the robot's reduced traverse speed, based on the distance from the operator. As a result, the operator can insert the component directly into the robot's gripper. At the same time, the operator has free access and a clear view of the process.

 Safety and Economy in Harmony
The robot's drives are safely deactivated while the component is inserted. If the worker leaves the infeed area's danger zone, the robot will slowly start to operate. As soon as the worker has left the warning zone, production will run at full speed. A safe stop in the infeed area / running the robot down safely while the workers are still in the infeed area saves on cycle times. As well as safeguarding the infeed area, safe robots also guarantee personal safety within the jigless cell through the software. As the robots can now move about close to the safety fence, the production area can be reduced, allowing for a compact body plant.

KUKA Robotics is the North American subsidiary of KUKA Roboter GmbH, one of the world´s largest robot manufacturers. Since building its first industrial robot in 1977, KUKA has earned an international reputation for robotic excellence. Virtually all of the 80,000 robots installed in the field use our PC-based controller, making KUKA the number one PC-controlled robot manufacturer in the world. KUKA offers a complete range of advanced design robots, covering all common payload categories, from 3 kg to 1,000 kg. Within this range you can always get the exact robot you need for your particular solution. Our PC-based controllers are easily expandable and offer cutting-edge technologies such as remote diagnostics, Windows interface, icon editor, fieldbuses, SoftPLC, OPC server.

Pilz and Komet: Modern Safety and Control Concept Leads to Greater Packaging Productivity

Faster, more flexible, safer – with this objective in mind, the level of automation on plant and machinery continues to advance in all industries. Both safety and control technology take these high requirements into account. If necessary, powerful components can be combined to form complete systems, which guarantee safety on the one hand, and can increase productivity on the other. If the user can adapt technology to suit his requirements, then he has a cost-effective, tailor-made solution. In many industries, packing is still associated with manual work. Where man and machine work together, the risk of injury must be minimized to the greatest possible extent. Safety devices used to be viewed as obstructive and inconvenient, but today the
opposite is true: modern safety and control concepts make handling easier, and plant and machinery more productive.

Faster thanks to the new safety concept
The semi-automatic vacuum-packing machine feeds in the bottom foil via a roller; it is then transported via a chain drive. The foil is brought up to temperature in the forming chamber; a special compressed air/forming procedure and the appropriate tool are used to create the desired tray shape for each packaged product. Staff use both hands to insert grilled sausages into the tray-shaped plastic film, six pieces per row and per pack, before the conveyor moves on and another set emerges from the forming station. After the filling station comes the sealing station: The top film seal is fed through a second roller; a vacuum pump extracts the air and thereby the oxygen. This slows down the activity of the micro- organisms, while the inflow of nitrogen prevents the sausage slices from sticking together. Finally, the top and bottom film layers are impulse sealed under pressure in the sealing chamber. The product packaging is now secure and durable. At the machine outfeed, longitudinal and transverse cutters separate the packaged product into individual trays, which are then fed into transport crates via conveyor. Two coils wind up the residual film cut from both sides. Sprinter is the name of the latest development from Komet, manufacturer of semi and fully automatic vacuum packaging machines. The company is based in Plochingen,Germany, and has its roots in the butchers' trade. It's in this field in particular that Komet's table-top units are used, as they provide an airtight seal for everything that needs to be kept fresh and preserved. Even in the butchers' industry there appears to be an irresistible trend away from the skilled producer and towards industrial production; customers increasingly ask for ready- packed goods, so Komet is increasingly focusing on semi and fully automatic machinery. Flexible and quick to convert, they can pack items in up to eight parallel trays, depending on the packaged product and the size, with or without automatic infeed. Even non-food goods can be packaged and sealed efficiently using  automated packaging machines.
Another reason why the machine is called Sprint is because, in comparison to the previous model Quickvac 2000, it can convey products to their packaging more quickly, using a less complicated procedure. That's because of a modern safety and control concept, which Pilz developed for Komet. Designed for maximum compatibility: sensor technology, evaluation device and visualization o n the Sprinter, the multifunctional safety system PNOZmulti configures simpler, safer interaction between man and machine. The safety system has a modular structure and can be used flexibly to suit the application. Instead of wiring, the user configures the needed functions simply, in a configuration tool. This saves time, space and money because there is no longer any complex individual wiring and all the safety related functions are located in one housing. PNOZmulti is cost effective when monitoring four or more safety functions and can also undertake standard control tasks. By comparison the safety devices on its predecessor were simplistic and mainly based on individually wired switches and contactors. Large covers safeguarded wide-ranging potential danger zones such as the forming and sealing stations via switch contacts. The infeed area in between was narrow and only allowed a one-up arrangement.
On the Sprinter, the cover on the forming station is reduced to a minimum. Instead, an advance security slide ensures that it is impossible to reach into either the forming or the sealing station from the filling station. If the slide switch is not closed, the safety system will prevent the bottom film from being formed and stop pressing and heat-sealing in the sealing station. Propulsion drives and valves are switched off; the central PMI operator
terminal (Pilz Machine Interface) receives an error message, stating the cause and the source. Magnetic safety switches, PSENmag, monitor the mobile protective hood over the sealing station, the longitudinal and  transverse cutters, and the lower positions of the lift cylinder plus the security slide on the forming/sealing station. The PNOZmulti also monitors the E-STOP and the enablers that control the heaters and valves (pneumatic + hydraulic). The risk of injury from the packaging machine, therefore, is kept to a minimum, both during operation and in setup mode. "With PNOZmulti the machine has a flexible safety concept which is really easy to adapt to our requirements. Now the infeed area has a three-up arrangement, so assembly is quicker and easier, plus the machine is more productive", says Harald Janke, Technical Manager at Komet.

Solution for safety and standard
A modern control solution also fell within the scope of the cooperation between Komet and Pilz. The standard control technology on the Sprinter also comes in useful for automatic operation and setup mode. "People at Komet were unhappy with the existing control solution and were looking for an efficient alternative", recalls Ralf Kessler, Applications Engineer at Pilz. Now they are using a PMI operator terminal in conjunction with a Profibus Master. A soft PLC runs under the Windows CE operating system. The standard I/O modules are logged and controlled via the PSSuniversal. The Pilz centralized control platform covers the whole I/O periphery as one system and is universally applicable. Users have three options: pure safety applications, combined safety and standard applications or exclusively conventional/standard control  functions.
With the grey, standard head modules it is possible to use analog and digital standard inputs and outputs on the fieldbus systems, without a functional connection to the safety technology. On the Sprinter, the head module of the PSSuniversal is also connected to the PMI via Profibus-DP, just like the PNOZmulti. Due to the system's modular design, the PSSuniversal can be individually adapted specifically to meet the respective requirement. If any adaptations are required, modules can simply be expanded or exchanged.

Benefitting from expertise
Pilz was also contracted to complete the electrical design, prepare the circuit diagrams and carry out the programming, including commissioning. "As a small company with around 30 staff we are reliant on competent, reliable partners for our electrical design and programming; we need partners who know what's happening and know what's important to us", says Janke, "Here we found Pilz to be a suitable partner, their technical advice was superb and the collaboration with the Pilz staff ran smoothly." The competence of Komet in terms of automation technology, combined with Pilz's expertise in matters of control technology and safety, jointly produced a new vacuum packing machine that operates more productively and is therefore of greater value.
Pilz is a global company, as such, not all standards and information will be applicable worldwide. Please check with your local Pilz office to ensure your factory and/or machines meet local standards.

Keeping it Safe: Pilz Keeps an Eye on Robots

This year Ford kicked it up a notch at the North American International Auto Show (NAIAS). The exhibit was 48 percent larger than last year with 24 interactive displays, including; Active Park Assist Technology, the Control Blade Challenge and touch-screen digital displays. With all of the excitement in the booth, the highlight of the show was the EcoBoost Engine display. The center of attention, ABB robots “Eco” and “Boost” showed off the components of Ford’s new engine technology. EcoBoost can deliver up to 20 percent better fuel economy, 15 percent lower CO2 emissions, and improved driving performance when compared to larger displacement engines. The two robots from Cleveland Stamping Plant #1 took on lives of their own while interacting with the audience and product specialists. How was visitor safety ensured? Pilz Automation Safety L.P. provided the display with SafetyEYE™, nicknamed “eyes in the sky” to ensure nothing entered the area over the cell. The robot control ran with an ATI tool changer end effector safety monitored by PSS 3000 to pick up parts and engines to present them to the audience. The Pilz PSS3000 was connected to the I/O proximity switches which sensed the part position to provide safe handling of the parts. The Pilz PLC was utilized as the main controller for both safe and standard functions controlling and ensuring all safety device functions. PITmode and PSENslock from Pilz were integrated into the PSS3000 to provide access control to the cell doors. PITmode was utilized as a multifunction HMI for switching between manual and automatic modes, resetting errors, starting up robots and request to enter and lock/unlock the gate. The PITmode is an operating mode selector switch which provides two functions in one unit, the selection of operating mode and authorization control for machine access. The PITmode was the result of a joint effort with Ford Powertrain Engineers and Pilz Development. “In the real world of a plant SafetyEYE™ could have eliminated hard guarding, in this case the glass fencing. ABB’s Safe Motion technology in conjunction with SafetyEYE™ provides a comprehensive robot cell that eliminates the use of standard guarding. This is really a great partnership for all parties involved,” said Rick Pryce, business development manager for Pilz Automation Safety L.P.

For more information about Pilz Automation Safety L.P. or any of the products used in the display visit www.pilz.us. 

Eco-electricity and heat from biomass

 Safety technology for a groundbreaking biomass power station

A biomass power station generates electric power by burning biomass like wood chips, bark and untreated wood. This is based on a high-tech process which has been modified in Oberwart, Austria. Here, the biomass is gasified under high temperatures in order to generate energy. Safety technology from Pilz makes sure that everything happens according to plan.

The technology behind wood gasification is not fundamentally new, as it has in fact already been known for several decades. Particularly in times of war or other crisis, during which there was often a shortage of fuel, vehicles were operated with wood gas engines. Of course, issues like "alternative production of energy" and "energy efficiency" were of no concern then. In the biomass power station in Oberwart, state-of-the-art wood gasification technology is used to achieve the maximum possible efficiency.
Today, the wood gas produced in the power station passes through a highly sophisticated purification process, and only then is it used to run two large gas engines. The electricity generated in this way is fed into the public grid. As a by-product of the system, large quantities of heat are also generated.

Special methods deliver high performance
Every year the biomass power station in Oberwart generates 16 GWh of eco-electricity and 21 Wh of heat. This is enough to supply around 4,300 households with electricity and around 1,600 households with heat.
The special technique used in the biomass power station is based on dual fluidized bed gasification technology. Here, the combustion zone and gasification zone are kept separate. Water vapor is used as the gasification agent. In this way, a product gas is generated in the gasification zone which is low in tar and virtually free of nitrogen. It also has a higher calorific value than the product gas obtained with other gasification methods.
With the technology applied here, the biomass power station in Oberwart is at the cutting edge in terms of efficient use of biomass for the production of eco-electricity and heat.

Flexible safety concept
In terms of safety, Ortner GmbH in Innsbruck/Tyrol who constructed the plant used the programmable PSS 3000 control system from Pilz for the first time. As a freely programmable system which is suitable for modular expansion, PSS 3000 can be flexibly adapted to the specific requirements of the plant. Looking at the required functionality, the number of inputs and outputs which needed to be integrated and the usability of the system, it became clear that this control system was the ideal solution for the safety requirements which needed to be implemented. It records and processes all safety-related messages and signals in the system, including the signals from the emergency stop, temperature and pressure sensors, lance monitoring and flame monitor systems. Networking of the signals into a standard PLC was implemented via the inputs and outputs.

Packaged with care

Foodstuffs must be packaged precisely, safely and carefully. When positioning or spacing products, it is particularly important to avoid flattening or damage during the packaging process.
The “Dynamic Stocker” accumulator made by the French firm Euro Cri converts an irregular product flow at the output of a production machine into a regular flow, as found when packaging biscuits, for example. The accumulator gathers the unpackaged products as they arrive and creates a “buffer store”, which can be regulated according to the change in the material flow.
The greatest challenge was to arrange the packaging process so that it was 100% synchronous with the rhythm of the existing horizontal flow-packer. The flow-packer forwards incoming products in an irregular sequence. Development and design demanded an automation solution capable of controlling complex movements and handle various transport speeds simultaneously. The focus was on the movement of a total of six axes. It had to be possible to coordinate the axis movements with 100% accuracy, so that the various speeds at different points of the conveyor could be synchronised precisely and safely regulated.
Euro Cri opted for a Pilz motion control solution (PMC), which enables precise synchronisation of the respective motion processes.

Complete packaging solution
As a supplier of complete automation solutions, Pilz France supported Euro Cri from planning and development to implementation and commissioning.
The central element of the motion control solution is the controller-based PMCprimo 16+, which performs the complex motion and control functions.
Used in conjunction with the servo amplifiers PMCtendo DD and servo motors PMCtendo AC, the result is a drive solution which can react flexibly to different format specifications and can be used to implement high cycle counts with ease. The absolute position of the motors can be read during operation, after the machine is shut down or after power failure. Systems with PMCtendo are modular and expandable. As a result, users can react flexibly to product changes. In addition to simplifying positioning and storing motion tasks, the PMCtendo DD also provides the power supply and motor drive on the “Dynamic Stocker”.

Packaging process is safely monitored
The packaging process can be monitored and regulated using PMIvisu operator terminals. The motion curves relevant for the cycle are calculated in the simplest way possible: the operator simply enters the set data on the operator terminal – the packaging length and the position of the section to be embossed, etc – and the system automatically calculates the motion profile for runtime. Adjustments are made via the operator terminal, whereby the material flow control system fulfils different product type requirements. The display can be used not only to select recipes but also to view error messages. The cause of the error always appears first; at the touch of a button the operator receives specific instructions on how to rectify the error.
Safety-related functions such as emergency stop, emergency off, or safety gate monitoring on the “Dynamic Stocker” are monitored via the compact safety relay PNOZsigma. The PSENmag safety switch was incorporated into the safety gate to ensure the packaging process is not interrupted unnecessarily; it is suitable for the very highest hygiene requirements and provides one hundred per cent protection against defeat.
“With Pilz we have gained a competent partner in the automation industry. We will continue to work with them in the future to develop leading-edge packaging systems for our customers,” says Mathieu Carie, Head of Automation at Euro Cri.



Author: Yannick Le Héno,
International Sales
Market Development
Pilz GmbH & Co. KG

Stanford Linear Accelerator Center- Laser Source Protection and Access Control

Stanford’s Linear Accelerator Center (SLAC) has built a safety and notification system for the variety of laser source equipment that is used at SLAC. The laser source safety configuration is designed with two major levels of protection; Access Control and Laser Source Protection. Pilz’s PNOZ Multi is used to monitor the status of the safety sensors and access control modules that are in place around the laser sources. The laser source itself is contained in a Laser Source area with entrances through various access doors and covers/flaps; these access points are all monitored using the Pilz PSENmag sensors. The PSENmag sensor status are monitored with a PNOZmulti, a Device Net Module is added to the system for annunciation of the safety system’s status. The access to the various laser sources and control areas while monitored by the PNOZmulti are used in conjunction with the Device Net Module, this allows those working in the Laser Source area to manage the status of access points to the laser. As part of the monitoring system, Pilz E-STOP pushbutton PIT is used to shutdown components during maintenance or configuration of the laser source or enclosure areas. The combination of safety products that SLAC has implemented thus far gives the several benefits from a safety design standpoint; the component nature of the system design itself, allows for a high degree of flexibility and reconfiguration allowing for the system to grow/change with minimal downtime. Additionally, the use of PNOZmulti monitors the amount of wiring involved in installation makes the safety system itself more economical. Finally, system status and safety diagnostics can be completed through use of a fieldbus as opposed to manual inspection, giving the system higher level of system integrity and accuracy. SLAC has plans to expand the safety system to create a more robust and efficient system for other areas of the SLAC research tools and equipment.

SLAC National Accelerator Laboratory is home to a two-mile linear accelerator—the longest in the world. Originally a particle physics research center, SLAC is now a multipurpose laboratory for astrophysics, photon science, accelerator and particle physics research. Six scientists have been awarded the Nobel Prize for work carried out at SLAC and the future of the laboratory promises to be just as extraordinary.

Schiphol Airport - Luggage Conveyor System Amsterdam, The Netherlands

Vanderlande Industries and Schiphol Airport made a joint decision to use Pilz PSS programmable control systems. The use of conventional relays was examined, however the different sectors and the respective shutdowns made it virtually impossible to implement the system using relay technology.

The PSS programmable control systems are connected via SafetyBUS p. This connection enables various areas to be shut down when different emergency stop buttons are operated or when different safety gates are opened.

The use of the Pilz PSS programmable control system allows Schiphol Airport and Vanderlande to connect to SCADA systems, provide precise fault analysis and perform complex safety options. The PSS programmable safety and control systems monitor safety functions such as E-STOP on extended conveyors. Integrated diagnostic functions enable faults to be located and rectified quickly. The low wiring costs and short commissioning times increase productivity and reduce costs.

With PSS programmable safety and control systems the conveyor system at Schiphol Airport meets the highest safety requirements in accordance with the international standards for machine safety EN 954-1, EN/IEC 62061 and prEN ISO 13849.

Vanderlande Industries designs, builds and services leading baggage handling systems for airports of all sizes. These belt, tub and/or track solutions combine operational effectiveness (low IR rates), short connection times and high conveyability. Based on proven technology, in-depth business knowledge and industry best-practices, they deliver the highest availability, reliability and lowest costs per bag. For more information about Vanderlandes other capabilities visit http://vanderlande.com