4 reasons why your automotive plant needs sensor-equipped safety zones

Oct 21, 2021

The increasing adoption of robot technology in the automotive industry is inevitable. After all, robot applications are more precise, deliver better quality products and ensure greater productivity at lower cost. What’s more, robots can work continuously, managing demanding, repetitive tasks with ease; ergonomics are not an issue. Robots might improve our working conditions, as human personnel will no longer be responsible for potentially hazardous tasks (e.g. moving heavy parts).

 

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blog-article-automotive-industry-and-safety-zones-image-1

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The greatest challenge in adopting these technologies is in ensuring that personnel can work alongside these robots safely, and without compromising productivity. 

This is where safety zone solutions – and especially smart sensors – prove essential. 

Here’s why:

1.The sensors in a safety zone have excellent range, even in challenging ambient conditions

Modern automation sensors use LIDAR-based technology built on High-Definition Distance Measurement algorithms, with a range up to 70m. They are robust and able to maintain a clear field of vision, even in unclear ambient conditions (e.g. in applications where dust is common). 

2. Sensors monitor continuously and with extreme precision

In a manufacturing environment, we can’t afford for safety measures to take breaks. Sensors provide continuous and precise monitoring, ensuring personnel safety round the clock and boosting productivity too. 

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blog-article-automotive-industry-and-safety-zones-image2.0

3. Sensors respond fast and don’t carry additional maintenance costs

Traditional mechanical or physical safety fences require an operator or technician to manage them. In this case, responses and start-ups are slower. Plus, over time, the mechanical items suffer wear and tear, adding to maintenance costs. 
 
On the other hand, sensors reduce the need for mechanical/physical fences altogether, allowing for more flexible workspaces and maximising the plant footprint.
 
With compact designs and industry-accredited software, sensors integrate into existing systems easily, ensuring a cost-effective solution.
 
With relatively few components, sensors do not require extensive maintenance. 
 
 

4. Sensors manage production automatically

Sensors are designed to communicate directly with PLCs and robots, to adjust equipment speed and take action automatically. Stopping times are reduced, resulting in improved efficiency and productivity. Less time is wasted managing mechanical controls or re-starting equipment after personnel have accessed the danger zone, the machinery or the goods in production. 
 
It is possible to embrace the future of robotics and automation to achieve competitive production, all while meeting safety requirements. Intelligent sensors are the cost-effective and efficient key, allowing robots and operators to collaborate.
 
A great example of this is SICK’s collaboration with OpiFlex (a Swedish robot company). OpiFlex sought to make its industrial robots mobile, to allow them to move to any location (or any client) as required. Using SICK safety devices, this is now possible – the robot can be moved using a pallet forklift truck or an automated guided vehicle and plugged into a previously installed platform. 
 
Two mini remote safety laser scanners, with the SICK Safe Robot system (S300 Mini Remote safety laser scanners) are mounted on the robot, and detect personnel around the robot site, slowing or stopping the robot as needed. No matter where the robot is deployed, it is safe, without the need for safety fences.  
 
For more information about SICK Intelligent Sensors’ safety solutions for your automotive plant, click here