Economical test systems with effective but not obstructive protection

Brainware Solutions needed a safety system for machines that test automotive door trims, which could guarantee a fast-running test routine while giving operators unobstructed, safe access to both test systems, so that they can be loaded and unloaded in time. For a solution, it turned to Pilz, which supplied a PSENscan safety laser scanner, combined with the PNOZmulti 2 configurable small controller, offering effective but not obstructive protection, so enabling minimum test times.

Based in Chemnitz, Germany, Brainware Solutions specialises in the manufacture of automated test systems. At the automotive supplier, Brainware Solutions’ test system is part of the production line, and the shortest possible test time is the top priority: only 23 seconds are envisaged for alternately loading and unloading the untested and tested door trims, plus the test itself.

The challenge is that the rear access areas also have to be protected. On their own, however, the pair of safety light curtains provided did not offer rear access protection. The solution was to add a safety laser scanner PSENscan to the safety concept. Installed centrally underneath the test system racks, it permanently scans a defined safety zone and provides reliable protection for the rear access area also.

Combined with the safe configurable small controller PNOZmulti 2, which is installed in the control cabinet, operators along with their direction of movement are reliably and safely detected, so they can focus on their inspection task safely, without restrictions. Today the test cycle is around a third faster, which has increased plant productivity.

Udo Jebok, project manager at Brainware Solutions, says: “Initially we thought about classic zone monitoring. As we have been using Pilz products and solutions for more than ten years and Pilz is a reliable system partner, it made sense to develop a solution together. Pilz has taken us a giant step forwards with this ingeniously simple and totally convincing solution.”