Pallet Transfer Safeguarding

In packaging applications, large boxes are placed on a pallet and shrink wrapped prior to being transferred for shipment. The main objective of safety applications is to protect operators while minimizing down time. Due to the dangers associated with a full pallet transfer, horizontal area guarding is needed in order to maximize productivity of packaging while protecting operators from the hazardous motion of a machine.

Banner’s AG4 Safety Laser Scanner offers a reliable safety solution for horizontal area guarding. With a 190º scanning angle, the AG4 covers a large area, which can be maximized by centering the scanner during installation. This can be any height for a 50 mm resolution, but should be mounted no lower than 300 mm for a 70 mm resolution.

The AG4 provides simple danger zone guarding and leg detection with the proper setup, creating a red Protective Field that initiates a complete shutdown if someone enters the field. Physically marking the area of the Protective Field is recommended in order to serve as an additional warning for individuals getting too close to the danger zone.

The AG4soft Wizard software is used to configure the two-dimensional shapes that will outline the Protective Field. The software offers a pre-determined application for quick and easy setup, and can store up to seven user configurable fields. With the flexibility of the AG4, new safeguarding shapes are easy to store and create in case work cell dimensions and parameters change. For a field pair switchover, external logic can activate one of the eight field pairs that are stored in the safety laser scanner.

Safeguarding a Single-Station Robot Weld Cell

The challenge in a single-station robot weld cell safeguarding application is to increase operator access to the weld station while effectively safeguarding the operator from the hazard. In this application, the operator places the part in the tooling station, leaves the open hazardous area, and then cycles the robot to begin work. When the robot completes the weld and moves to a safe state, the operator re-enters the area, removes the finished part, and begins a new cycle by placing a new part in the station. Using a safety scanner to safeguard the operator allows optimal access to the area, and can also increase productivity.

The Banner AG4 Safety Laser Scanner is placed at the base of the hazardous area and “looks out” at the open area. It is programmed via a PC with interface software to guard the area between the physical barriers (the protective zone) and outside the barriers (the warning zone). If the operator or other personnel approach the hazardous area during robot operation, a signal is sent to alert the person that the warning zone has been entered; the robot continues operation during this time. If the protective zone is entered, the robot and other hazardous machinery are stopped. This configuration reduces the number of nuisance trips and unnecessary down-time by warning personnel to stay out of the protective zone, and allowing the robot to continue its work cycle.

A safety laser scanner is a cost-effective safeguarding and productivity-enhancing solution to other safeguarding devices in this application. Safety mats are costly and deteriorate rapidly in high-traffic areas. Safety light curtains can be positioned to safeguard access to a hazard, but have no means of warning personnel that they are approaching the hazardous area, which can result in nuisance trips. Protective barriers using gates with safety interlocks effectively guard the area, but limit access for the operator and increase the amount of time between cycles. If the work station is reconfigured, the scanner can be re-programmed to adjust to the new work cell dimensions and parameters.

Area Guarding for Robotic Cells

When inspecting robotic results, it is important operators have access to the materials being inspected without compromising safety.

In this work cell, the robot picks up and places material in a package as it moves along the conveyor. The operator uses the inspection station to ensure the package was correctly filled. It is critical this individual does not enter the protective field (red area). A solution is needed that can detect intrusion, provide a stop signal, and continually sense the inspection station is imperative.

Safety laser scanners work well for safeguarding applications where user access and protection are equally important. Banner’s AG4 Safety Laser Scanner with a 190º scanning angle fits nearly any shape and can evaluate an operator’s position by range and rotational angle. Its flexibility allows for new safeguarding shapes when work cell dimensions and parameters change.

The AG4 also provides a warning field (green area) and a protective field (red area) within the designated safeguarding area to alert individuals who are getting too close to the robot before prompting a complete shutdown. When an object is detected, the AG4 calculates its position; the AG4 will allow the robot to continue to operate during warning field detection or will force a shutdown during protective field detection.

A safety laser scanner can be a cost-effective solution for safeguarding applications compared to other safeguarding options. Safety mats are often used in hazardous work cell areas, but they are costly and wear out quickly. Other machine safeguarding options include protective barriers and gates, which effectively safeguard an area, but limit the operator’s access. The AG4 Safety Laser Scanner allow optimal operator access to speed up the inspection process and increase productivity.