Machine Safety in focus

Anton Ivanov: Safe sensor technology refers to technologies that reliably collect data to monitor machine conditions and trigger safety measures when risks arise. In the food industry, this means that safety sensors must not only function precisely, they must also fulfil strict hygiene standards. Schmersal manufactures special safety sensors for this purpose, which are used in machines and production plants to detect dangerous situations and prevent accidents. Depending on the environment or requirements, magnetic, electronic or optoelectronic sensors are used that have been developed for demanding conditions.

Anton Ivanov: For the food industry, Schmersal offers a wide range of command and signalling devices as well as safety switching devices that meet the requirements of "hygienic design". Our safety switches and sensors also provide a wealth of data that contributes to production efficiency. Real-time data enables precise analysis of machine conditions, so that immediate action can be taken if necessary. This not only minimises downtime, it also helps to ensure compliance with hygiene standards. Schmersal offers safety sensors such as the contactless magnetic sensors of the BNS series, which offer high switching distances and protection against manipulation and have been specially developed for hygienic areas. Our 4D model (digital twin) also allows us to carry out virtual commissioning, which means that errors can be detected before the machine is actually built. This is an enormous advantage in cost-sensitive and time-critical production processes.

Anton Ivanov: One of the biggest challenges is to install sensors in such a way that they can be easily cleaned without compromising their functionality or reliability. Schmersal offers a wide range of sensors for this specialised application, including the CSS series, which uses pulse-echo technology, and the RFID-based RSS sensors. These electronic sensors are designed for safe use in dusty or dirty environments and meet the strict hygienic requirements of the food industry.

Particularly in the food industry, robust materials such as stainless steel enclosures are required, as these must be able to withstand frequent cleaning and temperature fluctuations. Our BNS 40S series magnetic safety switches have been specially designed to meet the high demands of food production. Thanks to their slim design and finely ground surface, they can be seamlessly integrated into the design of typical food processing machines. The robust stainless steel housing offers excellent protection against corrosion and is resistant to cleaning agents.

During installation, we take care to avoid dead spaces where residues could accumulate, while ensuring good accessibility of the sensors to facilitate regular cleaning. The sensor selection must fulfil the corresponding safety integrity level (SIL) or performance level (PL) to ensure safety and reliability. Safety sensors should also be tested at specified intervals to ensure functionality. Careful documentation of all installations, tests and maintenance is also required. Another important point is staff training, so that employees are trained to handle the sensors correctly.

Anton Invanov: The digital twin of our safety components simulates all the properties and functions of the physical devices as a fourth dimension (4D). The Schmersal Safety 4D model simulates not only individual components, but also entire processes and control sequences by means of the signal currents. The advantage of the 4D model is that, in addition to early error detection and optimisation, it will also be possible to virtually commission the machine in the future, even before the actual machine is mechanically constructed. This saves costs and unnecessary development loops.

Anton Ivanov: I see great potential in the further integration of artificial intelligence and machine learning in manufacturing. In the future, machines will not only be able to monitor conditions, they will also be able to learn independently and make adjustments to minimise risks and increase efficiency. In the field of safe sensor technology, I expect the trend towards multifunctional sensors that can simultaneously provide data for safety, efficiency and hygiene to continue. Our optoelectronic safety sensors, such as light barriers, light grids and light curtains, for example, are designed to meet the highest hygiene requirements while providing robust protection against dust and moisture.

Schmersal is working hard on the development of new digital technologies, such as cloud solutions and IoT applications, and also on new solutions that are specifically tailored to the requirements of the food industry. This is how we help our customers to increase the efficiency of their machines and systems while ensuring the protection of people and machines.

Contact:

Anton Ivanov
Industry manager for the Food, Beverage, Medical and Packaging sectors
Mail: aivanov@schmersal.com
K.A. Schmersal GmbH & Co. KG
https://www.schmersal.com/home