Developing a unified safety solution

Installed as part of a unified safety system, Flexi Soft from SICK ensures that each component in a network of safety controllers communicates effectively across a facility that welds large sections of steel together to enhance safety and visibility.

Following an incident at a steel processing facility where sections of steel are welded into continuous sections, Safety Systems Technology were called in to assist with additional protective measures. Safety Systems Technology developed and supplied a complete safety solution across the site, replacing a previous system comprising standalone safety concepts on some machines facilitating rope switches on conveyors. ​ The customer wanted a solution to provide an immediate safe ‘Global’ Emergency Stop to prevent future incidents and enhance safety and visibility on site.

Safety Systems Technology developed a single unified safety solution linking up machines and conveyors. The size and scale of the plant, to support large sections of steel profile, means conveyors are very long, with significant distances between local safety concepts. As part of the project to enhance safety throughout the plant, Safety Systems Technology looked at the potential to create a configurable safety network of ​ controllers.
 
Configurable safety
 
Having worked with intelligent sensor specialist SICK for many years, Safety Systems Technology selected the SICK Flexi Soft Solution to ensure that controllers communicate safely and effectively across large distances. Creating the largest span project in the UK, Safety Systems Technology used SICK Flexi Soft to daisy-chain field devices via Flexi Line, creating a unified safety system throughout the plant.
 
As part of the safety upgrade works, a network of local control panels located around the facility creates four zones of operation. These are connected to a new panel installed in the main Welding House to facilitate a site-wide ‘Global’ Emergency Stop function and Global Reset. This allows for the entire facility to be put into a safe state in the event of a hazardous situation. An overview of the whole system is displayed via a PLC on HMIs in real-time, supporting ease-of-use and transparency.

Easy installation

SICK Flexi Soft modular safety controllers can be easily installed and programmed via intuitive, license-free Flexi Soft Designer configuration software. The controllers are networked together over a SICK Flexi Line Interface network to provide an expandable and configurable safety system capable of addressing all required safety functions and future safety requirements, with continuous diagnostics down to the automation level. Capable of achieving Performance Level E (the highest performance level) in accordance with EN ISO 13849-1, the SICK Flexi Soft range allows for safe series connection and the local modular hardware platform allows the creation of tailored and efficient solutions for many different applications. SICK has a wide range of Flexi Soft modules available, all of which are easy to program, commission, and can provide continuous diagnostics via any fieldbus.

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