When operating automated vehicles, it must be ensured at all times that neither persons nor machines are harmed. In order to guarantee this in these circumstances, safe positioning of the AGV must be detected in accordance with PL d, while complying with standardized requirements such as documentation, calculation, etc. In addition to the highest precision and robustness of the sensor technology used, knowledge of the standards and guidelines, the development of a complete safety concept as well as calculation and validation are essential.

In this specific case, Pepperl+Fuchs provided the customer with an individual solution, encompassing every aspect from concept development to implementation.

AGVs should be reliably protected against collisions with people and objects in the lane when in automatic reverse travel, even if the vehicle is loaded. The blind spot in front of the fork arms must be secured in the phase instantly before lowering into the pallet. Approval according to ISO 13849-1 category 3 PL d is required for these application requirements. It should be possible to use these devices in confined spaces and they must be resistant to environmental influences such as dust, dirt, and humidity.

The USi®-safety is the only safe ultrasonic sensor system according to EN ISO 13849 category 3 PL d. It enables reliable monitoring of three-dimensional spaces, making it ideal for use on materials handling equipment.

Within a fleet of AGVs, different vehicles are often in use, so that different scenarios arise for them, e.g. when changing batteries or refueling, and the vehicles must be uniquely identified. In the case of hydrogen-powered vehicles, different tanks may be installed, each of which may only be refueled with a certain pressure. Since an error can cause great damage to people and machines, reliable identification is required.

Pepperl+Fuchs developed a customized complete solution for this, consisting of a safety concept and components. Two RFID transponders are attached to the vehicles for this purpose, which are suitable for use in harsh industrial environments—the required SIL level is ensured by redundancy and an evaluation of the transponder information in the safe control system.

With increased automation in industrial plants, the requirements for machine safety are rising, which also affects the packaging industry. For example, due to a change in the standard (EN 1010-1:2004 changed to EN ISO 12643-4), operator intervention in potentially hazardous areas of packaging machines must be prevented in the future with PL d instead of PL b in order to ensure the greatest possible personnel protection.

Pepperl+Fuchs offers an ideal solution that is not only cost-efficient, but also easy to integrate. The safety concept is based on two photoelectric sensors of the R100 series which guarantee the required safety level through their redundant design.