S3000 in a narrow aisle

Transcription

1 ADDENDUM OPERATING INSTRUCTIONS Safety Laser Scanner GB

2 Addendum Operating Instructions This document is protected by the law of copyright, whereby all rights established therein remain with the company SICK AG. Reproduction of this document or parts of this document is only permissible within the limits of the legal determination of Copyright Law. Alteration or abridgement of the document is not permitted without the explicit written approval of the company SICK AG. 2 SICK AG Industrial Safety Systems Germany All rights reserved /TL59/

3 Addendum Operating Instructions Contents Contents 1 About this document Regulations to be observed Operating conditions Installation and commissioning Example for determining the angular error on the industrial truck Mounting of the S Operating mode of the S Dimensioning of the protective field Required protective field length Required protective field width Example for the protective field configuration Example for maximum usable protective field length and stopping distance Example for protective field configuration for single-sided narrow aisle situation Test object Commissioning Checking the system Accessories /TL59/ SICK AG Industrial Safety Systems Germany All rights reserved 3

4 Chapter 1 About this document Addendum Operating Instructions 1 About this document Note This document is an original document. This addendum describes only the general conditions that must be observed on the usage of the. This addendum does not describe the properties and special features of the S3000 itself. This addendum only applies in conjunction with the original operating instructions S3000 Safety Laser Scanner (SICK part number , operating instructions S3000 Safety Laser Scanner in all available languages). The original operating instructions form the reference document and must be observed. 4 SICK AG Industrial Safety Systems Germany All rights reserved /TL59/

5 Regulations to be observed Addendum Operating Instructions Chapter 2 2 Regulations to be observed Along with the regulations stated in the operating instructions for the S3000 and in this application description, the following documents from the responsible Berufsgenossenschaft (Großhandel and Lagerei) (German trade association wholesaleing and warehousing) are to be observed: 1. Empfehlung für die Prüfung von Personenschutzsystemen an Flurförderzeugen für Schmalgänge von Hochregallagern (Recommendation for the thorough check on personnel protection systems on industrial trucks for narrow aisles in high-bay warehouses) 2. Checkliste für den Personenschutz in Schmalgängen (Checklist for the protection of personnel in narrow aisles) 3. Anforderungen bei bestimmungsgemäß gleichzeitigem Aufenthalt von Fußgängern und Regalflurförderzeugen in einem Schmalgang (Requirements on correct simultaneous presence in a narrow aisle of pedestrians and industrial trucks for accessing shelving) Can be obtained from Document 1 can be downloaded from the Internet at The documents 2 and 3 can be procured from the related committee: Geschäftsstelle Fachausschuss Förder- und Lagertechnik M5, Mannheim Tel. 0621/183-0 Fax 0621/ /TL59/ SICK AG Industrial Safety Systems Germany All rights reserved 5

6 Chapter 3 Operating conditions Addendum Operating Instructions 3 Operating conditions The S3000 type is a category 3 device for the protection of personnel in accordance with EN ISO 13849F1 and SIL 2 in accordance with IEC 61508/EN The S3000 is suitable for use on industrial trucks in narrow aisles. Taking into account document 3 in chapter 2 Regulations to be observed on page 5, usage is also possible on the correct simultaneous presence in a narrow aisle of pedestrians and industrial trucks for accessing shelving. The following notes relate to the mounting and the operation of the S3000, as per the work safety regulations Flurförderzeuge (Industrial trucks) (BGV D27) as well as DIN 15185, part 2. These regulations include, among other aspects: There must not be any aisles crossing the narrow aisles. Crossing aisles that are only provided as an emergency exit route for the operators are excluded from this requirement. The velocity of the vehicle must be reduced to creep speed, i.e. maximum 2.5 km/h, on leaving the narrow aisle. This requirement also applies on approaching the end of an aisle (blind aisle): Only creep speed is to be possible if the S3000 is bypassed by the driver. If the S3000 is shut down when the industrial truck leaves the narrow aisle, the shut down at the end of the aisle must comply as a minimum with category 2 in accordance with EN ISO 13849F1. The point for the shut down must be selected such that the path covered with the S3000 deactivated is as short as possible. After the vehicle has reentered a narrow aisle, the S3000 must be switched back on automatically. For safe operation with high availability, goods must not protrude beyond the front of the shelf in the narrow aisle after storage. Otherwise, operation of the stacker with the stipulated distance between the protective field and the front of the shelf will not be possible. In addition, at these heights retroreflectors are not permitted. Exceptions are reflectors at the start and end of the narrow aisle for the detection of the ends of the aisle with which the S3000 is activated on entry into the aisle and deactivated on leaving the aisle. The protective field dimensions allowed for the protection of narrow aisles as given in section in Fig. 4 on page 9 and in section in Tab. 1 on page 11. The play on the guidance of the industrial truck has a significant effect on the reliability of the detection and the availability of the entire system. The maximum permissible angular error relative to the symmetrical middle position for the industrial truck in the narrow aisle is ±0.3. The related value pairs for the distance between the guide elements for the industrial truck and maximum play per guide element are given in section 4.1, Fig. 1 on page 7. 6 SICK AG Industrial Safety Systems Germany All rights reserved /TL59/

7 Installation and commissioning Addendum Operating Instructions Chapter 4 4 Installation and commissioning 4.1 Example for determining the angular error on the industrial truck Fig. 1: Maximum permissible play per guide element as a function of the distance between the guide elements on the stacker in the direction of travel for the maximum permissible angular error of ± 0.3 At a distance between the guide elements on the industrial truck of 1.8 m, the maximum permissible play per guide element is ±0.5 cm (see Fig. 1). Determination of the guide play at the vehicle: For mechanical guides: If the guide elements on the left are in contact with the guide rail (0 cm play) the distance between the elements on the right and the rail is allowed to be a maximum of cm = 1 cm. For inductive guides: The industrial truck is allowed to diverge from the guide line by a maximum of ±0.5 cm. Max. play per guide element [cm] Distance between the guide elements on the stacker in the direction of travel [cm] 4.2 Mounting of the S3000 Notes The following points are to be noted when mounting the S3000: For reasons of availability (pitching movements of the industrial truck) the bottom edge of the S3000 housing should be at least H S3000 = 50 mm above the floor. For applications in mixed operation, the sensor must be mounted with the protective field horizontal or pointing down slightly. The latter is recommended as a measure against glare (e.g. sun) or mutual interference (several sensors). For such applications the scanner must be mounted such that the scan plane is a maximum of 200 mm high. In this way persons lying down will be reliably detected. We recommend aligning the scan plane at 150 mm. When driving forwards the lifting device (fork) must be raised sufficiently such that the protective field on the S3000 is unoccupied. Here the work safety regulations BGV D27 12, sections 2 and 3, are to be observed /TL59/ SICK AG Industrial Safety Systems Germany All rights reserved 7

8 Chapter 4 Note Installation and commissioning 4.3 Operating mode of the S3000 Addendum Operating Instructions Using the CDS user software, the following parameters are to be set: Definition of the type of restart: Provided complete monitoring of the area in front of the industrial truck is possible (see Tab. 1): Without a time delay if the maximum distance from the middle of the S3000 to the front of the shelf on the left or right is D S3000 Shelf 150 cm. Time delayed by 2 s if the maximum distance from the middle of the S3000 to the front of the shelf on the left or right is 150 < D S3000 Shelf 250 cm. With restart interlock if it is possible to stand behind the protective field in front of the industrial truck due to the mounting position of the S3000. Definition of the application variant: mobile Note that setting multiple sampling will have an effect on the response time of the scanner and therefore on the stopping distance of the industrial truck. 4.4 Dimensioning of the protective field Fig. 2: Dimensioning of the protective field The size of the protective field is defined by means of the length of the protective field at which the industrial truck comes to a standstill under all conditions before the load or the vehicle contour come into contact with people. Maximum protective field radii of up to 4.0 m (S3000-S), up to 5.5 m (S3000-M) and up to 7.0 m (S3000-L) can be programmed. the protective field width at which people or the test object in accordance with Fig. 3 are reliably detected in the boundary area in front of the shelf. The unmonitored area of width D PFFShelf (see Fig. 2) between the protective field and the front of the shelf is necessary due to the angular error on the industrial truck and the measuring accuracy of the S3000 and should be as small as possible. definitive for the dimensions of the protective field is the final test on the reliability of detection in accordance with section 4.6 Commissioning on page 15. Test object D PF Shelf Guide rail X PF Shelf Max. protective field radius 700 cm Shelf Protective field length L PF < 700 cm S3000 D S3000 Shelf Forklift (without fork) 8 SICK AG Industrial Safety Systems Germany All rights reserved /TL59/

9 Installation and commissioning Addendum Operating Instructions Chapter 4 Fig. 3: Test object and positioning Front of shelf D TO Shelf 120 mm 800 mm 500 mm Guide rail 70 mm Notes During the design of the protective field ensure the field is adequate to prevent a hazard. Note that the CDS function Protective field suggestion is unsuitable due to the random actual position of the vehicle in the aisle and the yaw movement of the vehicle as it moves along the aisle. All S3000 variants provide the required resolution of 70 mm at the max. protective field radius. As a result only the bottom cylindrical part of the test object is relevant Required protective field length During the determination of the necessary protective field length by driving trials, the parameters are to be set in the vehicle to produce the longest stopping distance. As a rule these are: the maximum velocity that can be achieved the maximum load to be expected and the maximum load dimensions to be expected When performing the braking trials, observe the following: Forward and reverse motion are to be checked separately. Perform at least 5 driving trials in each direction of movement. The stopping distance L Stop comprises the distance covered during the response time of the S3000 as per the operating instructions, the response time of the controller and the braking distance. Determine the stopping distance with action of the protective field only /TL59/ SICK AG Industrial Safety Systems Germany All rights reserved 9

10 Chapter 4 Installation and commissioning Addendum Operating Instructions The length of the protective field to be programmed L PF is to be calculated as follows: L PF = L Stop L Fork + S PF Where: L Stop = Maximum stopping distance 1.1 = Supplement 10% of the stopping distance for wear on the brakes L Fork = Fork length or maximum distance from the mounting position for the S3000 to the front edge of the load. S PF = Protective field supplement from Tab. 1 For the measurement error on the S3000 For the effect of the inclination of the protective field on the effective, horizontal protective field length To compensate for the increasing distance between the middle of the test object and the front of the shelf with increasing aisle width to suit the rule for supplements. The rule for supplements states that for each cm movement of the test object from its original position (12.5 cm) in the direction of the middle of the narrow aisle, a supplement of 20 cm must be applied to the protective field length. The maximum distance from the middle of the test object to the front of the shelf that can be assumed is 20 cm (see Tab. 1). The maximum permissible protective field lengths as a function of the distance from the middle of the S3000 to the front of the empty shelf are defined in Tab. 1 on page 11 and shown in Fig. 4. The usable protective field length L use for the stopping distance including brake supplement and fork length is given by the maximum protective field length L max after deduction of the supplement S PF and is shown in Fig. 4 in grey (see Tab. 1): L use = L max S PF Fig. 4: Maximum and usable protective field length as a function of the distance D from the middle of the S3000 to the front of the shelf or half protective field width W L max = Maximum protective field length L use = Usable protective field length Maximum and usable (grey) protective field length (cm) Narrow aisle protection Restart Without time delay Narrow aisle protection Restart Time delayed after 2 s Single-sided aisle protection: (see section 2.4.5) Restart Without time delay < D < D < D < D < D < D 400 Distance D from middle of S3000 to front of the shelf or half protective field width W (cm) 10 SICK AG Industrial Safety Systems Germany All rights reserved /TL59/

11 Installation and commissioning Addendum Operating Instructions Chapter Required protective field width The distance D PF Shelf between the protective field and the front of the shelf to be programmed is given in Tab. 1 as a function of distance D S3000 Shelf from the middle of the S3000 to the front of the empty shelf. The distances D S3000 Shelf are to be determined for an industrial truck in the middle of the narrow aisle at an angular error of 0 for the left and right protective field width. If the S3000 is mounted off-centre on the industrial truck, the larger supplements S PF for the wider half protective field are to be used, however the protective field distances D PF Shelf correspond to the width on the left and right. The left or right protective field width X PF is given by Tab. 1 from the following formula: X PF = D S3000 Shelf D PF Shelf (see Fig. 2) Tab. 1: Distance between protective field and front of shelf Distance middle of S3000 to front of shelf D S3000 Shelf [cm] D < D < D < D 250 Type of restart Without time delay Time delayed after 2 s Distance test object D TO Shelf [cm] Maximum protective field length L max [cm] Protective field supplement S PF [cm] Usable protective field length L use [cm] Protective field length L PF [cm] Protective field distance D PF Shelf [cm] L max Example for the protective field configuration Stopping distance L Stop = 350 cm, Fork length L Fork = 120 cm Off-centre mounting of the S3000 on the industrial truck: Distance on left from S3000 to front of shelf D S3000 Shelf = 100 cm Distance on right from S3000 to front of shelf 120 cm The test object must be detected at the following distance from the front of the shelf: In front of the shelf on the left at a distance D TO Shelf = 15 cm In front of the shelf on the right at a distance D TO Shelf = 16 cm Required protective field width X PF : Depending on the protective field length L PF, 4 to 8 corner points must be programmed, see Tab. 2. For examples for protective field lengths 0 cm and 100 cm, see Tab. 3 and Tab. 4: Left protective field width X PF = D S3000 Shelf D PF Shelf = = 90.5 cm Right protective field width X PF = = cm /TL59/ SICK AG Industrial Safety Systems Germany All rights reserved 11

12 Chapter 4 Installation and commissioning Addendum Operating Instructions Required protective field length L PF : Left half of the protective field: L PF = L Stop L Fork + S PF, 100 cm = = 575 cm Right half of the protective field: L PF = L Stop L Fork + S PF, 150 cm = = 595 cm The larger value is to be used for the right half of the protective field L PF = 595 cm. The permissible protective field length for the right half of the protective field is L max = 623 cm, see Tab. 1. During the configuration of the S3000 using the user software S3000 (see section 4.3 Operating mode of the S3000 on page 8), the application variant mobile is to be set. If it is not possible to program a permissible corner point because the permissible protective field length L max or the maximum measuring radius of 700 cm is exceeded, then with a constant X value, reduce the Y position until a permissible value L max is achieved. The programmed protective field length and width must always be larger or equal to that required. The protective field width on the right or left can, if necessary, be changed by slightly moving the S3000 transverse to the direction of travel of the industrial truck and as a result the necessary protective field length then programmed. For the left half of the protective field the following is found: On the entry of set values X PF = 90.5 and Y PF = 0, the value is rounded up to the next largest safety-related value X PF = 91 cm. On the entry of the set values X PF = 91.5 and Y PF = 598, the values X = 92.0 and Y = 598 are found. The permissible and programmable co-ordinates for the protective field corner points are summarised in Tab. 2 and Tab. 3. Tab. 2: Example values for the left half of the protective field D S3000 Shelf D PF Shelf [cm] Entries in CDS Protective field length [cm] Position X [cm] Values realised by CDS Position Y [cm] = = = = Tab. 3: Examples values for the right half of the protective field D S3000 Shelf D PF Shelf [cm] Entries in CDS Protective field length [cm] Position X [cm] Values realised by CDS Position Y [cm] = = = = SICK AG Industrial Safety Systems Germany All rights reserved /TL59/

13 Installation and commissioning Addendum Operating Instructions Chapter Example for maximum usable protective field length and stopping distance Fork length L Fork = 200 cm Distance S3000 front of shelf 150 cm The maximum protective field length that can be used for the stopping distance including the brake supplement and the fork length in accordance with Tab. 1 is here: L use = L max S PF = 623 cm 93 cm = 530 cm. From the protective field length L use, after the deduction of the fork length and based on the maximum stopping distance of the industrial truck for the narrow aisle width given, including the response time of the sensor and controller and the factor for brake wear of 1.1, the following is found: L Stop (L use L Fork ) : 1.1 ( ) : 1.1 = 300 cm Example for protective field configuration for single-sided narrow aisle situation Tab. 4: Maximum protective field length for single-sided narrow aisle situation In applications with a single-sided narrow aisle situation (see Fig. 5), the S3000 can be programmed on the open side to have a half protective field width of 7 m. The maximum protective field lengths allowed outside a narrow aisle reduce to values defined in Tab. 4 and shown in Fig. 4 due to the resolution of the S3000. Half protective field width W [cm] Maximum protective field length [cm] W < W < W < W < W < W < W < Depending on the distance from the middle of the S3000 to the front of the shelf, the supplement S PF is to be added to the necessary protective field length as per Tab. 1. A supplement of S W = 10.0 cm is to be added to the protective field width on the open side. This supplement takes into account the maximum measurement error on the S3000 and is independent of the protective field length /TL59/ SICK AG Industrial Safety Systems Germany All rights reserved 13

14 Chapter 4 Fig. 5: Industrial truck with single sided narrow aisle situation Installation and commissioning Guide rail Addendum Operating Instructions D PF Shelf with L PF Protective field width < 700 cm Protective field supplement S W = 10.0 cm Shelf SF Max. protective field radius 650 cm Protective field length L PF < 700 cm D PF Shelf with L PF = 0 cm Example Width of the industrial truck 320 cm Stopping distance L Stop = 200 cm Off-centre mounting of the S3000 on the industrial truck Distance on left from S3000 front of shelf D S3000 Shelf = 60 cm Distance on right from middle of S3000 to the right vehicle contour of 270 cm Required protective field width X PF Left protective field width, as per section and Tab. 1 on page 11: X PF = D S3000 Shelf D PF Shelf = = 50.5 cm for protective field length 0 cm and 100 cm. X PF = D S3000 Shelf D PF Shelf = = 51.5 cm for protective field length 200 cm and L max cm. Right protective field width: X PFRight = Distance middle of S3000 vehicle edge + Worst case measurement error X PFRight = cm = 280 cm Required protective field length L PF Left half of the protective field: L PF = L Stop S PF (100 cm) = = 290 cm Right half of the protective field: The value for the left half of the protective field is to be used. Checking the protective field dimensions Left half of the protective field: The permissible protective field length for the left half of the protective field is L max = 623 cm and is therefore larger than the example value required of 290 cm. Right half of the protective field: The permissible protective field length in accordance with Tab. 4 for a width on the right of 280 cm is 300 cm and is therefore larger than the example value required of 290 cm. 14 SICK AG Industrial Safety Systems Germany All rights reserved /TL59/

15 Installation and commissioning Addendum Operating Instructions Chapter 4 Note 4.5 Test object The test object available as an accessory must be set up as per Fig. 3 and Tab. 1 for the driving trials on the detection reliability. The top edge of the test object must always be at a height of 80 cm above the floor. All S3000 variants provide the required resolution of 70 mm at the max. protective field radius. As a result only the bottom cylindrical part of the test object is relevant. 4.6 Commissioning Before commissioning the industrial truck, ensure by means of at least 20 driving trials that the test object is detected in the distance from the middle of the test object to the front of the shelf in accordance with Tab. 1 and an industrial truck stops in time under the conditions that result in the longest stopping distance. As a rule this will be: The maximum achievable velocity. The maximum load to be expected. The maximum dimensions to be expected for the load. The trials are be performed 5 times in each direction of travel for the front of the shelf on the left and the right. Documentation of the driving trials and settings is to be included in the test certificate required in accordance with the work safety regulations BGV D Checking the system To ensure detection is reliable, the mounting of the S3000, the guide play and the braking action on the industrial truck are to be checked regularly. 4.8 Accessories S3000 accessories: see S3000 operating instructions Accessories for use in a narrow aisle Test object with fixing bracket Application description Test object fixing bracket /TL59/ SICK AG Industrial Safety Systems Germany All rights reserved 15

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