Feature Safety sensors Light barriers keep VW safe
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Feature Safety sensors T he press-shop at Emden includes two large capacity crossbar presses with a total press capac- ity of 73,000kN, running at a speed of up to 15 strokes per minute. The high capacity presses help create the 20,000 pressed parts per day, while consuming vast volumes of sheet metal. The movement of these parts plus moving large die-tools, requires carefully controlled production sys- tems, which include machine safety protection from Leuze electronic. Steel blanks are stacked onto RFID tagged pallets, which are used to trans- port the sheets around the press shop. To optimise the material flow to match the production demand, these pallets and hence the sheets can be placed into an automated heavy load shelving system for interim storage. Staff safety is a top priority in the press shop and during tool change, pressing tools weighing several tons are driven on automated transfer vehi- cles. To provide protection for the workers, the danger areas surrounding where the transfer vehicles operate are guarded by Leuze electronic’s Robust safety light barriers. The Robust safety light barriers used in the tool change areas are in some locations installed in UDC equipment columns. These columns have springs in their base to provide an automatic return to the correct position after a mechanical knock or importantly in this applica- tion to provide immunity to vibrations from the presses. Pressings are examined within a measuring room, using a measurement robot, with Leuze electronic’s Compactplus safety light barrier being used to protect workers. The Compactplus range offers an inte- grated muting function which cleverly enables pressings to enter and exit uninterrupted, but prevents personnel from entering a danger area and coming to harm. Integration of this safety control functionality within the curtain rather than within a separate control panel offered a faster original installation and because the curtains are self-contained there are fewer cables and no control panel within the measuring room. The highest possible levels of relia- bility are required to ensure continu- ous material flow within the automotive industry as they are in other demanding industries such as materials handling and food and drink packaging. For this reason Leuze elec- tronic carefully designs and manufac- tures its sensors to provide a performance reserve enabling reliable operation in real-world applications. Leuze electronic offers a wide port- folio of safety products which are complemented by its machine safety inspection service. Leuze electronic T: 01480 40850 www.leuze.co.uk Enter 403 Light barriers keep VW safe Volkswagen’s factory at Emden on the north-west coast of Germany near the border with Holland, manufactures the VW Passat. Its press shop supplies 20,000 pressed parts each day and relies upon Leuze electronic to help protect its workforce from the dangers of large loads and tooling dies moving around Light curtains protect operators on high-speed printing press P rinting systems manufacturer and market leader in web offset manroland AG’s Colorman offset print press is a premium system not only because of its flexible handling of colour and dynamic production changes, but also because it features an Automatic Plate Loading (APL) system with reliable safety sensor systems from Leuze electronic. The APL is a robotic system for full-automatic loading of the Colorman’s printing cylinders with printing plates. The dimensions and weight of the cylinders plus the high-speeds involved in the change-over of the printing plate meant manroland wanted to ensure press operators safety and chose safety light curtains from Leuze Electronic’s SOLID range. These long-lasting and versatile sensors suit machines demanding high system availability and few industries demand this more than the print industry. The Colorman uses the self-testing SOLID-2E safety light curtains of type 2, (IEC/EN 61496), and SIL 2, (IEC 61508 & IEC/EN 62061). Despite being robust, the curtains have a slim aluminium housing, measuring 30 x 34mm which fitted perfectly in the press enclosure. The SOLID-2E safety light curtains feature high interference rejection which prevents even the frequent overspray of ink near the printing cylinder affecting its reliability. After the operator has arranged the new plates and removed the used plates, he leaves the area near the printing cylinder and initiates the loader from a control panel alongside the machine’s front. The safety light curtains then ensure operators cannot approach the moving automatic plate loader as it swivels an arm towards the new plates and uses suction to pick up the pre-programmed number of plates. It then swivels back to the cylinder and deposits the plates. As the swivel arm returns to its resting position, the cylinders turn and the printing process begins. With the APL module, even existing Colorman systems can easily be retrofitted keeping in line with manrolands motto of modularity when constructing printing systems and designing them for maximum efficiency. The Leuze electronic safety light curtains on the printing plate changer are an important component in realising this. Leuze electronic T: 01480 40850 www.leuze.co.uk Enter 404 APRIL 2010 Machine Safety Supplement S12 Picture - manroland AG A VW Passat in the press shop where machine safety from Leuze is required A high-bay crane at the Emden factory Steel blanks are stacked onto RFID tagged pallets AUTO-APR10-PGS12:Layout 1 16/04/2010 13:37 Page 12
Transcript of Feature Safety sensors Light barriers keep VW safe
Feature Safety sensors
The press-shop at Emden includestwo large capacity crossbarpresses with a total press capac-ity of 73,000kN, running at a
speed of up to 15 strokes per minute.The high capacity presses help createthe 20,000 pressed parts per day, whileconsuming vast volumes of sheetmetal. The movement of these partsplus moving large die-tools, requirescarefully controlled production sys-tems, which include machine safetyprotection from Leuze electronic.
Steel blanks are stacked onto RFIDtagged pallets, which are used to trans-port the sheets around the press shop.To optimise the material flow to matchthe production demand, these palletsand hence the sheets can be placedinto an automated heavy load shelvingsystem for interim storage.
Staff safety is a top priority in thepress shop and during tool change,pressing tools weighing several tonsare driven on automated transfer vehi-cles. To provide protection for theworkers, the danger areas surroundingwhere the transfer vehicles operate areguarded by Leuze electronic’s Robustsafety light barriers. The Robust safety
light barriers used in the tool changeareas are in some locations installed inUDC equipment columns. Thesecolumns have springs in their base toprovide an automatic return to thecorrect position after a mechanicalknock or importantly in this applica-tion to provide immunity to vibrationsfrom the presses.
Pressings are examined within ameasuring room, using a measurementrobot, with Leuze electronic’sCompactplus safety light barrier beingused to protect workers. TheCompactplus range offers an inte-grated muting function which cleverly
enables pressings to enter and exituninterrupted, but prevents personnelfrom entering a danger area andcoming to harm. Integration of thissafety control functionality within thecurtain rather than within a separatecontrol panel offered a faster originalinstallation and because the curtainsare self-contained there are fewercables and no control panel within themeasuring room.
The highest possible levels of relia-bility are required to ensure continu-ous material flow within theautomotive industry as they are inother demanding industries such asmaterials handling and food and drinkpackaging. For this reason Leuze elec-tronic carefully designs and manufac-tures its sensors to provide aperformance reserve enabling reliableoperation in real-world applications.
Leuze electronic offers a wide port-folio of safety products which arecomplemented by its machine safetyinspection service.
Leuze electronicT: 01480 40850 www.leuze.co.uk Enter 403
Light barriers keep VW safeVolkswagen’s factory at Emden on the north-west coast ofGermany near the border with Holland, manufactures theVW Passat. Its press shop supplies 20,000 pressed partseach day and relies upon Leuze electronic to help protectits workforce from the dangers of large loads and toolingdies moving around
Light curtains protect operators on high-speed printing press
Printing systems manufacturer and market leader in web offset manroland AG’s Colorman offset print press is apremium system not only because of its flexible handling of colour and dynamic production changes, but also
because it features an Automatic Plate Loading (APL) system with reliable safety sensor systems from Leuze electronic.The APL is a robotic system for full-automatic loading of the Colorman’s printing cylinders with printing plates. The
dimensions and weight of the cylinders plus the high-speeds involved in the change-over of the printing plate meantmanroland wanted to ensure press operators safety and chose safety light curtains from Leuze Electronic’s SOLID range.
These long-lasting and versatile sensors suit machines demanding high system availability and few industries demandthis more than the print industry. The Colorman uses the self-testing SOLID-2E safety light curtains of type 2, (IEC/EN61496), and SIL 2, (IEC 61508 & IEC/EN 62061). Despite being robust, the curtains have a slim aluminium housing,measuring 30 x 34mm which fitted perfectly in the press enclosure. The SOLID-2E safety light curtains feature high interference rejection which prevents even the frequent overspray of ink near the printing cylinder affecting its reliability.
After the operator has arranged the new plates and removed the used plates, he leaves the area near the printing cylinder and initiates the loader from a control panel alongside the machine’s front. The safety light curtains then ensureoperators cannot approach the moving automatic plate loader as it swivels an arm towards the new plates and uses suction to pick up the pre-programmed number of plates.It then swivels back to the cylinder and deposits the plates. As the swivel arm returns to its resting position, the cylinders turn and the printing process begins.
With the APL module, even existing Colorman systems can easily be retrofitted keeping in line with manrolands motto of modularity when constructing printing systemsand designing them for maximum efficiency. The Leuze electronic safety light curtains on the printing plate changer are an important component in realising this.Leuze electronic T: 01480 40850 www.leuze.co.uk Enter 404
APRIL 2010 Machine Safety SupplementS12
Picture - manroland AG
A VW Passat in thepress shop wheremachine safetyfrom Leuze isrequired
A high-bay crane atthe Emden factory
Steel blanks arestacked onto RFIDtagged pallets
AUTO-APR10-PGS12:Layout 1 16/04/2010 13:37 Page 12
