Industrial Robot Safety Systems for BTR Systems
Project
BTR Systems, a brand that is part of the Blachotrapez Group, offers durable and reliable stone-coated roofing. The highest quality of its products is confirmed by the longest warranty on the market — 60 years.
Projekt: Industrial Robot Safety Systems for BTR Systems
BTR Systems approached us in connection with the purchase of two sheet metal forming lines. The client asked us to implement additional safety devices and mechanisms. The goal was to fully meet machine safety requirements in accordance with the Machinery Directive and applicable standards.
Location: Bochnia, Poland
Project Description
To ensure full safety on the line, we used mechanical components as well as automation and robotics assemblies. These assemblies included elements designed by our engineers, allowing the safety solution to be tailored as closely as possible to the existing lines. From the purchased mechanical components, we primarily used a safety fencing system by Protec.
This system was supplemented with mounting elements and additional protective mesh panels, designed and manufactured by PROSTER.
The electrical and automation assemblies we used were purchased for the construction of three control cabinets mounted on-site and on the fencing. These mainly consisted of:
- Control stations — Pizzato, EATON
- Safety locks and limit switches — Pizzato
- Safety controller with I/O modules — Wieland SAMOS series
- Actuating components — SIEMENS, EATON, FINDER
Robot Safety Zone Simulations
The robots on the production line were to be positioned in tight zones. For this reason, we used software that allowed us to programme virtual safety zones. In other words, within the software we granted the robot “permission” to move within the specified zones, and then transferred these restrictions to the real production environment. This reduced the time required to configure movements on the actual robot. This approach significantly increases safety for operators performing tasks in the vicinity of the robots.
The entire scope of works was completed with the electrical connection, programming and commissioning of the robotic workstations, which had been supplied by a Korean company
Project Challenges
- Limited space in the hall, both in terms of floor area and the positioning of the line relative to the building walls and access routes
- Adapting appropriate safety solutions to the existing production lines and their structures, including the use of non-standard (lowerable) fencing panels on one of the lines
- The need to select and implement appropriate automation solutions to enable full integration and signal exchange between the production line devices
The project involving the commissioning and integration of new production lines with automated collection was another major challenge carried out in collaboration with PROSTER. The choice of this particular integrator was not insignificant, given the previous extensive and fruitful cooperation on the integration of production lines in a newly established plant, as well as the implementation of a SCADA system in the production area. In this case too, PROSTER demonstrated great commitment and swift execution of the task, which translated into maximum reduction of the line start-up time and the launch of serial production — and consequently, the rapid expansion of our product range with the newly manufactured products.
Production Plant Director, BTR Systems
Benefits for the Partner
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Enhanced safety level
for operators performing tasks in the vicinity of robots and for the processed product
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Minimised workstation configuration time
through safety zone simulations in a virtual environment
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Flexibility in applying solutions
In addition to off-the-shelf components, we created our own, dedicated specifically to this particular line
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Delivery with a proven partner
confirmed by an ISO 9001 quality management system certificate (see footer)
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No need to coordinate works across different scopes
thanks to the execution of the entire scope of mechanical, automation, robotics and electrical works
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Maximum reduction of production start-up time
a tym samym szybkie wzbogacenie gamy wyrobów klienta o nowe produkty
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