Herma sticks to Leuze for warehouse safety and positioning … · 2012. 8. 6. · Herma sticks to...
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H erma specialises in the manufacture of self-adhesive labels and label machines. It operates one of the world's most advanced coating plants and this facility is supported by a high-bay warehouse where manufactured material on rolls is stored and subsequently conveyed to the cutting machines and the packaging lines for ultimate despatch to global customers. The entire warehouse is automated and its operation is reliant on a large network of sensors and safety devices supplied by Leuze electronic. Following the flow of materials through the warehouse starts at the goods receiving area where paper and foil rolls are unloaded from trucks and placed on a lifting table by a clamping truck (figure 1). A Leuze Solid-2E safety light curtain with a protected field height exceeding 2m can be seen on the right of this picture, as can a Leuze BCL 80 high-speed barcode reader, mounted on the ceiling. Precision positioning of the rolls is achieved with the aid of a Leuze BPS 34 barcode positioning system, which is entirely optical in operation and thus avoids any mechanical wear and slippage issues, and removes the need for reference points. A vertical conveyor transports the roll to the interior of the goods receiving hall where a fully automatic gripper gently places it on a transport system pallet. This transport system pallet uses Leuze 46B series retro-reflective photoelectric sensors (Figure 2) to detect presence, exact position and to supply signals to the fire door control. Solid-2E light curtains are also deployed in this area. Storage in the high-bay warehouse Transport carts, the position of which is determined by another BPS 34 barcode positioning system, transport the rolls to the storage hall, where they are received by one of the two high-bay storage cranes. Here a Leuze DDLS 200 data transmission photoelectric sensor (visible on the wall and the side of the high-bay crane in Figure 3) continuously transmits the position data of the high-bay storage crane directly to the control system PLC. The position of these high- bay cranes is also ascertained using the BPS 34 barcode positioning system (a red sensor and the continuous tape of barcodes can be seen in figure 4). Another feature of the high-bay storage area, is the use of Rotoscan RS4 safety laser scanners to protect maintenance staff when entering the storage aisle danger area. An RS4 laser scanner mounted on the high-bay crane close to floor level (the yellow safety sensor, which can be seen in figure 4) reliably safeguards the traversing area and, if a person enters the danger area of a moving crane the system shuts down. Thus if one high-bay crane is shut down for maintenance, the other is able to continue to work, providing that the safety laser scanner does not detect it approaching the maintenance worker's location, in which case it will also be shut down. Transport portal and distribution cars The raw materials required for an order are retrieved from the high-bay storage unit on a 'channel car' and delivered to the In this and the article following on page 20, we take a closer look at the benefits of the single-supplier approach to automation. Here, we discover how a major manufacturer of self-adhesive labels entrusted virtually all of the key sensing and safety monitoring functions for an automated high- bay warehouse project to a trusted supplier partner Herma sticks to Leuze for warehouse safety and positioning systems 18 March 2010 DRIVES & AUTOMATION SUPPLEMENT Figure 1: a clamping truck delivers the rolls to the goods receiving area Figure 2: 46B series retro-reflective photoelectric sensors ensure reliable positioning of the rolls along all transport paths Figure 3: the DDLS 200 data transmission photoelectric sensor transmits the position data of the high-bay storage device directly to the system PLC
Transcript of Herma sticks to Leuze for warehouse safety and positioning … · 2012. 8. 6. · Herma sticks to...
Herma specialises in the manufacture of self-adhesivelabels and label machines. It operates one of theworld's most advanced coating plants and this facility
is supported by a high-bay warehouse where manufacturedmaterial on rolls is stored and subsequently conveyed to thecutting machines and the packaging lines for ultimatedespatch to global customers. The entire warehouse isautomated and its operation is reliant on a large network ofsensors and safety devices supplied by Leuze electronic.
Following the flow of materials through the warehousestarts at the goods receiving area where paper and foil rollsare unloaded from trucks and placed on a lifting table by aclamping truck (figure 1). A Leuze Solid-2E safety light curtainwith a protected field height exceeding 2m can be seen onthe right of this picture, as can a Leuze BCL 80 high-speedbarcode reader, mounted on the ceiling.
Precision positioning of the rolls is achieved with the aid ofa Leuze BPS 34 barcode positioning system, which is entirelyoptical in operation and thus avoids any mechanical wear andslippage issues, and removes the need for reference points.
A vertical conveyor transports the roll to the interior of thegoods receiving hall where a fully automatic gripper gentlyplaces it on a transport system pallet. This transport systempallet uses Leuze 46B series retro-reflective photoelectricsensors (Figure 2) to detect presence, exact position and tosupply signals to the fire door control. Solid-2E light curtainsare also deployed in this area.
Storage in the high-bay warehouse Transport carts, the position of which is determined byanother BPS 34 barcode positioning system, transport therolls to the storage hall, where they are received by one of
the two high-bay storage cranes. Here a Leuze DDLS 200data transmission photoelectric sensor (visible on the walland the side of the high-bay crane in Figure 3) continuouslytransmits the position data of the high-bay storage cranedirectly to the control system PLC. The position of these high-bay cranes is also ascertained using the BPS 34 barcodepositioning system (a red sensor and the continuous tape ofbarcodes can be seen in figure 4).
Another feature of the high-bay storage area, is the use ofRotoscan RS4 safety laser scanners to protect maintenancestaff when entering the storage aisle danger area. An RS4laser scanner mounted on the high-bay crane close to floorlevel (the yellow safety sensor, which can be seen in figure 4)reliably safeguards the traversing area and, if a person entersthe danger area of a moving crane the system shuts down.Thus if one high-bay crane is shut down for maintenance, theother is able to continue to work, providing that the safetylaser scanner does not detect it approaching themaintenance worker's location, in which case it will also beshut down.
Transport portal and distribution cars The raw materials required for an order are retrieved from thehigh-bay storage unit on a 'channel car' and delivered to the
In this and the article following on page 20, we take a closer look at thebenefits of the single-supplier approach to automation. Here, we discoverhow a major manufacturer of self-adhesive labels entrusted virtually all of
the key sensing and safety monitoring functions for an automated high-bay warehouse project to a trusted supplier partner
Herma sticks to Leuzefor warehouse safetyand positioning systems
18 March 2010
DRIVES & AUTOMATION SUPPLEMENT
Figure 1: a clamping truck delivers the rolls to thegoods receiving area
Figure 2: 46B series retro-reflective photoelectric sensors ensurereliable positioning of the rolls along all transport paths
Figure 3: the DDLS 200 data transmission photoelectric sensortransmits the position data of the high-bay storage devicedirectly to the system PLC
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19March 2010
roll-out conveyor. Here, the roll is unpacked and transferred via a fullyautomatic transport portal, which was specially designed for Herma.This portal either stores the roll in a buffer or transports it directly tothe roll unwinding/winding machine via a distribution car (shown inFigure 5)
At the transport portal/distribution car interface, Leuze's Robustseries multiple light beam safety devices are used to safeguard theaccess points to the danger areas (Figure 6).
Numerous Leuze PRK 96 retro-reflective photo-electric sensorscontrol the start/stop function at the transfer station. The grippers forthe rolls are also equipped with retro-reflective photoelectric sensorsand BPS positioning systems.
Jak Pluder, who is responsible for technology and maintenance atthe Herma facility believes the co-operative relationship built over anumber of years with Leuze personnel really has paid dividends on thislatest project. He expresses particular satisfaction with the company'sability to come up with novel technical solutions to the many problemsthat present themselves during the course of such a complicatedproject. "For all of the special tasks and exceptional requirements inautomation, be it detection, positioning or safety-related sensorsystems, we can count on Leuze's employees to be at our side withhelp and advice."
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Figure 4: a Rotoscan RS4 safety laser scanner reliably safeguards the areanear the storage aisle. Also shown is a BPS 34 barcode positioning systemfor the high-bay storage device
Figure 5: distribution cars, which function according to the 'mother-daughter'principle, are also equipped with Leuze electronic sensors
Figure 6: Robust series multiple light beam safety devices safeguard accesspoints to the danger areas at the transport portal
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