Light curtains excel in an automated warehouse

The simultaneous operation of automated vehicles, conveyors, and stacker cranes elevates the risk at entry and exit points, underscoring the need for robust safety measures without disrupting the smooth flow of materials.

This challenge was tackled in a significant project undertaken by an OEM specialising in intelligent industrial systems. Central to the initiative was a three-dimensional automated storage and retrieval system (ASRS) designed for integrated handling, storage, and picking alongside the production line at a prominent premium household appliance maker. To ensure safe operations across this complex setting, the OEM partnered with ReeR Safety.

At the heart of the solution was the installation of over 100 pairs of EOS4 safety light curtains strategically located at workstation entrances across the three levels of the warehouse. These EOS4 units create an invisible yet dependable barrier between personnel and moving loads. They permit the movement of goods while instantly responding to a human attempting to cross their path.

However, relying solely on light curtains wouldn't suffice in maintaining efficiency. A sophisticated coordinated sensor system was integrated to differentiate between packages and people. As goods approach, two pairs of frontal photoelectric sensors detect their presence, signalling the automated vehicle to halt perfectly at the transfer point. A diagonal sensor then communicates with the conveyor, confirming readiness for the exchange. Throughout this exchange, the EOS4 curtain monitors the area - muting is activated to allow a package to pass through, but if a person is detected, the system promptly triggers a stop, ensuring safety is paramount.

The careful integration of sensors and safety light curtains guarantees that muting cannot be misused or triggered by misleading actions. This results in a system that is both efficient and robust against tampering. Operators remain safeguarded as the automated flow of goods continues unimpeded.

The outcomes are clear: an effective balance between productivity and safety has been achieved, significantly reducing both false alarms and downtime while fully adhering to international machine safety standards. Most importantly, this application illustrates how thoughtfully designed safety technology can enhance rather than hinder the efficiency of sophisticated logistics operations.