AG4 Series Safety Laser Scanner Application Guide
Contents
1. BANNER more sensors more solutions AG4 Series Safety Laser Scanner Application Guide The AG4 Scanner the Scanner can provide a protective function only when its settings and connections software configuration Protective and Warning Field dimensions electrical interfacing mounting environmental conditions supplemental safeguarding etc are coordinated with its application The checklist items below and the following application examples are intended to give additional guidance in applying the Scanner Direct any questions to Banner Engineering at the numbers on the back page Application Check List Items The following items are provided to assist in creating a checklist or to be included in a risk assessment for the application of the Scanner Additional items may be required depending on the application see Section 3 of the Scanner User Manual p n 144924 NOTE When Section and Figure numbers are referenced in this document they refer to sections and figures in the User Manual v Review the Scanner User Manual in particular Sections 1 5 and 1 11 v Identify the appropriate application e g required resolution field orientation etc Area Guarding Danger zone guarding Area Guarding Leg detection Leg detection danger zone guarding Vertical Guarding Hand Detection Hand protection point of operation Vertical Guarding Arm Detection Arm protection point of operation Vertical Guarding2. 500 mm 20 The possibility of crushing trapping hazard against the overhanging conveyor and the transfer cart is an application specific addition for this example The total Protective Field length Minimum Distance from the Scanner to the leading edge of the Protective Field is 1895 mm 75 e Protective Field Width Additional Side Distance Z The Z factors to determine the Protective Field width are primarily the same as above Zsm 83 mm Zrefi 0 Zr 100 mm but the application specific adder ZasipE is now used to account for the entire area to the sides the cart and under the overhang of the conveyor This distance is 300 mm 12 Zsm ZF 183 mm 7 3 thus Za must equal 117 mm 4 7 to ensure the entire area to the sides of the cart are monitored The total width of the Protective Field for this example is 1666 mm 66 which is the width of cart of 1066 mm 42 plus the value of the two 300 mm side distances e The 190 Protective Warning Field option should be used to minimize any unmonitored area at the Scanner s sides e The vehicle s maximum speed should be identified in the Scanner s configuration In this example the maximum speed is 1200 mm s so the up to 1500 mm s option would be chosen e The Warning Field is used to slow the transfer cart and sound a horn if an object is detected e The design of the transfer cart ensures that there are no protruding loads e g pallets that could become a haza
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4. Body Detection Body protection danger zone guarding Access Perimeter Guarding Passage Control access guarding AGV Automated Guided Vehicle Mobile vehicle Determine the area to be safeguarded and the Scanner s installation location and means Determine whether the Scanner requires protection from mechanical damage Ensure that the environmental conditions do not exceed the Scanner specifications Determine the size and coverage of the Protective Field and Warning Field if used depending on o Physical location of the Scanner installation o The minimum safety distance Sections 3 3 4 and 3 3 5 or the stopping distance of the mobile vehicle Section 3 4 3 o The height H of the Protective Field horizontal applications o Other factors that may require an increased minimum safety distance e g shadowing adjacent Scanners retro reflective surfaces brake performance degradation NOTE It is recommended to visibly mark the Protective Warning Field boundaries if possible O O 0 0 0 ASSA v Determine whether the Reference Contour Monitoring function is required at least two sides must be defined as reference contour or surface v Assess the possibility of avoiding detection by the Scanner by climbing stepping over crawling under moving around the protection field s either at the perimeter of the fields or in unprotected areas caused by the shadow effect v Determine whether additional supplement safeguarding
5. adder is equal to 78 mm U S formula This gives a safety distance of Ds 1600 mm s x 0 08s 0 08s 0 025s 78 mm 374 mm 14 7 In other words the plane of the Protective Field must be no closer than 374 mm 14 7 from the nearest hazard The use of the Reference Contour Monitoring function is required for vertical guarding applications i e the blue shaded areas In this example no factors would require an increase in the safety distance Because there is no pass through hazard see Section 3 3 6 the Scanner can be configured for automatic Sstart restart reset However the machine control circuitry must be designed so that one or more initiation devices must be engaged i e a conscious act is required to start the machine Further any initiation devices or reset switches must comply with Section 3 3 7 For the purpose of this example the UM FA 9A Universal Inout Safety Module was used and interfaced in a control reliable category 3 or 4 method as described by Section 3 and Figure 3 19 AG4 Scanner Applications Guide P N 147900 rev A 03 2010 6 Example 5 Vertical Guarding Access Guarding whole body detection with Reference Contour Monitoring The application below uses two Scanners with Field Pair Switchover to safeguard a pallet load unload station The two Protective Fields per Scanner are enabled the red lines and disabled pink shaded areas as pallets are loaded unloaded and as they enter exit the
6. does not move or otherwise become repositioned negatively affecting safety distance or otherwise creating voids or gaps or other access to the hazard SOO NEN WSS w A iW TTI Typical considerations for vertical guarding when detection of the hand or arm is required The typical application selection in the AG4soft program is Hand protection point of operation i e Vertical Guarding Hand Detection with a resolution of 30 mm In this example the Scanner is mounted in the center of the opening facing down to maximize the available size of the Protective Field and to minimize the accumulation of dust on the Scanner s front screen window In this example physical damage is not expected because the Scanner is mounted above and away from the probable path of the material being placed into and being removed from the guarded area The typical manufacturing setting is well within the Scanner s environmental ratings The size and coverage of the Protective Field must ensure that the hazard cannot be accessed by moving reaching around under or over the Protective Field Access to the hazard is prevented by the Protective Field overlapping the machine frame and maintaining the proper safety distance For this example assume a machine stopping time of 80 ms Scanner response time of 80 ms the response time of a safety interfacing device UM FA 9A safety module is 25 ms Because the resolution is fixed at 30 mm the Dpf
7. dures nterlocked Gate Safety Light Screen In addition to the typical considerations for horizontal stationary area guarding listed in example 1 e Install multiple Scanners with a vertical offset height of 100 mm or more or use physical shielding to prevent one Scanner from interfering with another Scanner see Section 3 3 2 e Be aware of the effect of needle and cone shaped fields and eliminate areas of unreliable detection see Section 3 3 1 e Eliminate the shadow effect see Section 3 3 1 and or use additional safeguarding e Configure the Scanner for start restart interlock manual reset to ensure that the Scanner does not turn ON its safety outputs if an individual is momentarily undetected e g climbs up onto the machinery above the plane of the Protective Field e Also configure any perimeter guarding systems e g an interlocked gate or safety light screen for a manual reset any reset switches must comply with Section 3 3 7 e Use the Reference Contour Monitoring function to monitor whether a gate is open or closed AG4 Scanner Applications Guide P N 147900 rev A 03 2010 5 Example 4 Vertical Guarding Point of Operation hand detection with Reference Contour Monitoring In applications in which the Scanner s Protective Field is positioned vertically to detect a hand an arm or an entire body the Reference Contour Monitoring function must be used This is to ensure that the Protective Field
8. er These edges will detect the torso of an individual 150 mm resolution is typically selected In addition to the typical considerations for mobile area guarding listed in example 6 e 150mm resolution is selected for torso detection Other resolutions e g 70 mm can be selected depending on the application e The leading edge of the vertical Protective Field should be no shorter smaller than the corresponding horizontal Protective Field assuming that the response times and safety distances are equal e Position the vertical Protective Fields at a slight angle so that the lower Protective Field edges protrude over the vehicle width by the amount of the additional distances Zsm Zr ZReFL and Za when required see example 6 e The configuration of a reference contour as with other vertical guarding applications is not required because the approach of the individual is detected by the edge of the Protective Field and not the plane As with the horizontal Protective Fields the vertical Protective Field must be checked verified on a periodic basis e Crushing trapping hazards can be minimized by supplemental safeguarding such as by preventing access e g fencing or causing the individual to be detected by the leading edge of the horizontal Protective Field AG4 Scanner Applications Guide P N 147900 rev A 03 2010 11 more sensors more solutions Banner Engineering Corp 9714 Tenth Ave North Mpls MN 55441 Tel
9. erlock manual reset to ensure that if an individual interrupts an active Protective Field while attempting to enter the guarded area that the Scanner s OSSD safety outputs remain OFF until manually reset after the individual exits the cell For the purpose of this example the UM FA 9A Universal Input Safety Module was used and interfaced in a control reliable category 3 or 4 method as described by Section 3 and Figure 3 19 AG4 Scanner Applications Guide P N 147900 rev A 03 2010 7 Example 6 Mobile Area Guarding on Transfer Carts Trolleys and Automated Guided Vehicles AGVs On mobile applications such as transfer carts the Scanner monitors the area directly ahead of the cart using both the Warning and the Protective Fields If something is detected within the Warning Field the green area the alarm output signals the vehicle logic to slow the vehicle and sound a horn or other awareness device The Scanner stops the vehicle when something is detected within the Protective Field the red area If the speed increases or decreases alternate Field Pairs can be used to adjust for varying stopping distances see example 7 Typical considerations for mobile vehicle guarding horizontal fields The typical selection for the application in the AG4soft program is AGV Automated guided vehicle i e Mobile vehicle with a resolution of 70 mm In this example the mobile vehicle is a transfer cart that travels in two directions al
10. figure the Scanner to power up with the appropriate Field Pair in the Scanner Start table e g allow power up with FP 1 only FP 2 only or either Field Pair e For this example the Permitted Field Pair switchover table should be configured to allow switching from FP 1 to FP 2 and from FP 2 to FP 1 e In higher risk applications that require control reliability category 3 or 4 interfacing it is highly recommended to use redundant sensors or switches to initiate or enable a Field Pair change AG4 Scanner Applications Guide P N 147900 rev A 03 2010 4 Example 3 Stationary Area Guarding with Multiple AG4 Scanners Area Guarding is frequently used in conjunction with other safeguards such as interlocked gates on fencing or vertically positioned safety light screens grids i e perimeter guarding The purpose of the safeguarding located at the perimeter of the work cell is primarily to detect entry into the hazardous area while the area guarding i e the Scanner is responsible for preventing machine restart or other machine hazards while the individual remains within the work cell In such applications it is important not to have any voids or unmonitored areas dead spaces in the detection capability of the Area Guarding system The Scanner can be configured for irregularly shaped protection fields to accomplish this Important Area Guarding and Perimeter Guarding should not be used in place of Lockout Tagout proce
11. ft side PF right side PF both sides PF and no Protective Field When no pallets are at the station the front Scanner has a Protective Field that covers both sides the rear Scanner has no Protective Field enabled to allow pallets to be fed into the station i e pallets exiting the cell As pallets are loaded sensors monitoring the pallet position switch the Field Pairs to turn off the front Scanner s right side and turn on the rear Scanner s Protective Field for that side as shown This allows the forklift to pick up the pallet and remove it When the front Protective Field is inactive the pallet must completely block the opening to prevent access When the pallet is removed that Protective Field must immediately be re activated The use of the Reference Contour Monitoring function is required for vertical guarding applications i e the blue shaded areas For this example assume a machine stopping time of 200 ms Scanner response time of 80 ms safety interfacing device UM FA 9A safety module response time is 25 ms Because the resolution is fixed at 150 mm the Dpf adder is equal to 900 mm U S formula This gives a safety distance of Ds 1600 mm s x 0 2s 0 08s 0 025s 900 mm 1388 mm 54 6 In other words the plane of the rear Protective Field must be no closer than 1388 mm 54 6 from the nearest hazard assuming no hazard inside the load station Configure the Scanner for start restart int
12. is required v Determine the proper startup start restart manual automatic reset and other safety relevant parameters If the start restart interlock manual reset is used determine the position for the reset button v Determine whether Field Pair switchover is required and identify the conditions for its use Section 1 12 4 v Determine the method and means of electrical interfacing dependent on the level of risk determined by the risk assessment e g OSHA ANSI control reliability or ISO 13849 1 category 3 PLd AG4 Scanner Applications Guide P N 147900 rev A 03 2010 1 Contents Example 1 Stationary Area Guarding Horizontal Danger Zone Guarding Example 2 Stationary Area Guarding with Field Pair Switchover Example 3 Stationary Area Guarding with Multiple AG4 Scanners Example 4 Vertical Guarding Point of Operation hand detection with Reference Contour Monitoring Example 5 Vertical Guarding Access Guarding whole body detection with Reference Contour Monitoring Example 6 Mobile Area Guarding on Transfer Carts Trolleys and Automated Guided Vehicles AGVs Example 7 Mobile Area Guarding with Field Pair Switchover Example 8 Mobile Area Guarding with Side Vertical Guarding AG4 Scanner Applications Guide P N 147900 rev A 03 2010 Example 1 Stationary Area Guarding Horizontal Danger Zone Guarding Area Guarding uses a horizontal sensing field i e Protective or Warning Fields to continually sense an ind
13. ividual within a safeguarded area Area Guarding can reduce or eliminate the possibility of a pass through hazard see Section 3 3 6 that could result in an individual being exposed to unexpected machine startup or motion As an individual approaches the Warning Field the green area can illuminate a warning beacon or sound an alarm that the Protective Field the red area is about to be entered In conjunction with markings on the floor the use of a Warning Field can eliminate intermittent stopping due to individuals being unaware of the safeguarded area When iy Typical considerations for horizontal stationary area guarding e The typical selection for the application in the AG4soft program is Leg detection danger zone guarding i e Area Guarding Leg detection with a resolution of 50 mm e Inthis example the Scanner is mounted in the center of the operator work station to maximize the available size of the Protective and Warning Fields The Scanner is mounted directly to the cell s perimeter guarding fencing 300 mm above the floor to prevent crawling under the Protective Fields e Inthis example physical damage is not expected because the fencing provides adequate protection If interference with the operator is expected the Scanner can be recessed into the fencing to minimize exposure e The typical manufacturing setting is well within the Scanner s environmental ratings e The size and coverage of the Protective Field
14. must ensure that the hazard cannot be accessed by moving reaching around under or over the Protective Field Access to the hazard is prevented by the fencing along the side of the Protective Field which minimizes the required floor space e For this example assume a robot stopping time of 100 ms Scanner response time of 80 ms the response time of a safety interfacing device is 25 ms UM FA 9A safety module Because an individual can reach over the detection plane by bending at the waist the Dpf adder is equal to 1200 mm U S formula and the Measurement Tolerance Factor Zsm must be accounted for This gives a safety distance of Ds 1600 mm s x 0 1s 0 08s 0 025s 1200 mm 83 mm 1611 mm 63 In other words the leading outside edge of the Protective Field must be 1611 mm 63 from the nearest hazard e It is recommended to mark the boundary of the Protective Warning Field on the floor The use of the Reference Contour Monitoring function can prevent shifting of the Protective Field and is recommended for stationary applications e This example has no factors that would require an increase in the safety distance e There is no possibility of easily stepping climbing or otherwise avoiding detection e Because there is no pass through hazard see Section 3 3 6 the Scanner can be configured for automatic start restart reset However the machine control circuitry must be designed so that one or more initiation devices m
15. ong a pair of rails Each direction of travel is guarded by separate individually configured Scanners on either end of the vehicle mounted 150 mm 5 9 above the plane of the floor not the rails The plane of the Protective Field should not exceed 200 mm 7 9 above the floor In this example physical damage is not expected because the path of travel is restricted The typical manufacturing setting is well within the Scanner s environmental ratings Continued on next page AG4 Scanner Applications Guide P N 147900 rev A 03 2010 8 Example 6 continued e Protective Field Length Minimum Distance D For this example assume a maximum vehicle speed of 1200 mm s 48 s a breaking distance of 900 mm 35 Scanner response time of 160 ms the response time of a vehicle drive and safety interfacing 100 ms which results in an overall stopping distance of 1212 mm 48 Dsp 1200 mm s x 0 1s 0 16s 900 mm This value is added to the Additional Distance Factors Z to determine the Protective Field length which for this example are Zsm 83 mm 3 3 The farthest point of the Protective Field from the Scanner along a radial is less than 3500 mm 138 which is at far corners Zrett 0 The possibility of retro reflectors located within the scanning plane of the Protective Field can be excluded Zr 100 mm 4 to the The ground clearance of the transfer cart s sides is 60 mm 2 4 and the wheels are not accessible Za
16. ound to be defective at the time it is returned to the factory during the warranty period This warranty does not cover damage or liability for the improper application of Banner products This warranty is in lieu of any other warranty either expressed or implied
17. rd e The fencing Supplemental safeguarding along the path of the transfer cart reduces the risk of an individual stepping directly in front of the cart this allows the Protective Field width to be minimized The fencing also reduces but does not eliminate the possibility of crushing trapping hazards between the transfer cart and the conveyor because the individual is detected by the leading edge of the Protective Field e Inthis example the movement of the transfer cart is controlled primarily by on board logic that is safety rated This allows the movement to begin after the material control system conveyor logic commands the cart to a specific location Automatic start and restart automatic reset function must incorporate a two second delay after the Protective Field becomes clear per BS DIN EN 1525 e The on board logic of the transfer cart that controls beginning and stopping motion and the means of electrical interfacing must be evaluated during the risk assessment to meet the required level of safety performance e g control reliability or category 3 or 4 AG4 Scanner Applications Guide P N 147900 rev A 03 2010 9 Example 7 Mobile Area Guarding with Field Pair Switchover Similar to the transfer cart on rails in example 6 the Scanner protects people who are located in the path of an Automated Guided Vehicle AGV As in example 6 the distance between the Protective Field front edge and the vehicle front must be greater than
18. the stopping distance of the vehicle at its selected soeed and at maximum load As the AGV approaches a turn the on board logic slows the speed to prepare for the turn at which time the Protective Field can be reduced by switching to an alternate Field Pair AGVs that have a complicated motion path that includes turns to either the left or right can use multiple Field Pairs to look around a corner The control system selects soeed dependent Protective Fields and can activate side Protective Fields when the vehicle is turning As a corner is approached the primary Field Pair the green and red areas guarding directly in front of the AGV is switched to an alternate Field Pair the green and red shaded areas that allow the AGV to make the turn without the larger primary Protective Field detecting a column or wall In addition to the typical considerations for mobile area guarding listed in example 6 e When utilizing Field Pair switchover the Minimum Distance D and Side Distance Z Protective Field length and width must be calculated individually for all Protective Field pairs e Ahorn light or other awareness means should be used to signal the approach and the turning maneuver as supplemental safeguarding to alert an unaware individual of the approaching hazard if the AGV is in a blind spot e g around the corner e The Field Pairs allowed at startup enabled at Scanner powerup and which Field Pair switchovers are permitted m
19. ust be engaged i e a conscious act is required to start the machine e Further any initiation devices or reset switches must comply with Section 3 3 7 e For the purpose of this example the UM FA 9A Universal Input Safety Module was used and interfaced in a control reliable category 3 or 4 method as described by Section 3 and Figure 3 19 AG4 Scanner Applications Guide P N 147900 rev A 03 2010 3 Example 2 Stationary Area Guarding with Field Pair Switchover An Area Guarding application can use the Field Pair Switchover function to automatically allow access to one area while simultaneously guarding another hazardous area This can improve machine cycle efficiency by allowing the operator to remove place parts while the operation is in a different area for example The robot position i e the location of the hazard is monitored to identify when no hazard exists at one work station at which time the Field Pairs are switched The Field Pair Switchover function is much like a muting application for a safety light screen In addition to the typical considerations for horizontal stationary area guarding listed in example 1 for this example e Ensure that no individual is exposed to a hazard while employing the Field Pair switching function The risk assessment should determine the applicability of this function means of selecting Field Pairs in respect to failure modes and whether supplemental safeguarding is required e Con
20. ust be identified in the Scanner s configuration Only those combinations that are necessary should be allowed e The on board logic of the AGV that controls beginning and stopping motion the means of selecting switching the Field Pairs and the means of electrical interfacing must be evaluated during the risk assessment to meet the required level of safety performance e g control reliability or category 3 or 4 AG4 Scanner Applications Guide P N 147900 rev A 03 2010 10 Example 8 Mobile Area Guarding with Side Vertical Guarding Vertically guarding the sides of transfer carts material handling trolleys and Automated Guided Vehicles AGVs prevents contact with objects that may have overrun the stop position of a conveyor which could result in damage to the mobile vehicle and the conveyor This type of guarding can also be used for situations which have the possibility of a crushing trapping hazard e g a distance less than 500 mm 20 between the sides of the Scanner and a physical structure Two Scanners are positioned to create horizontal Protective Fields to prevent running over objects or individuals in the path of the vehicle A second pair of vertically mounted Scanners is positioned to detect objects at or above the horizontal plane of the Scanners that are looking ahead of and behind the vehicle In this configuration the leading edge of the Protective Field is now provided by the vertical edges on the sides of the Scann
21. work cell at the rear of the station The Scanner s FP inputs are used to identify the position of a pallet to determine which Protective Field to disable The Reference Contour Monitoring blue shaded areas ensures that Protective Fields are in the proper position N g VV N In addition to the typical considerations for vertical guarding listed in example 4 In the example shown above the objective is to prevent an individual from entering an area thus detecting the body torso is required The typical application selection in the AG4soft program is Body protection danger zone guarding i e Vertical Guarding Body Detection with a resolution of 150 mm In this example Scanners are mounted in the center of the two entry exit points to allow switching of the Protective Field depending on whether access is required to the left or to the right In this example physical damage is not expected since the Scanner is mounted above and away from the probable path of the forklift If impact is possible a mechanical guard shroud can be added to protect the Scanner without blocking the Protective Fields The typical manufacturing setting is well within the Scanner s environmental ratings The size and coverage of the Protective Field must ensure that unrestricted or accidental entry to the work cell is prevented Two Scanners are used to create four Protective Fields to cover each end of the pallet load unload Station i e le
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