The challenges and trends with safety in the demanding world of battery production
For more than a decade SICK has been developing innovative software solutions for the demanding world of battery production. In this interview, Clifford Cox, an experienced safety expert at SICK, provides valuable insights into the greatest challenges and the latest trends in the industry.
Find out how modern sensors and automation technologies can improve safety in highly automated production processes, and the necessary measures for avoiding accidents and injuries.
What are the biggest safety challenges when manufacturing batteries in highly automated gigafactories, and how do customers deal with these?
Cox: As a safety expert at SICK, I regard the most important safety challenges in highly automated gigafactories to ensure safety and efficiency. In these complex environments, it is crucial that both employees and machines are optimally protected and function smoothly. One of the biggest challenges is that the machines come from regions such as Asia and do not meet European standards. This can lead to safety management problems.
How can sensors and automation increase safety in production processes?
Cox: Sensors and automation play a crucial role in increasing safety in production processes by minimizing human error and ensuring consistent, precise operations. At SICK, we rely on sensors that can be seamlessly integrated into production systems and continuously monitor the environment to avoid accidents.
An example of this is the manual loading points of electrode rollers. This is where a deTec safety light curtain or the safeVisionary2 3D safety camera sensor can detect an employee and prevent the machine from carrying out a potentially dangerous movement while the employee is present in the hazard zone.
Using the correct safety switch can also be very important for processes like electrode drying, calendering and cutting. A safety switch with locking function such as the flexLock can ensure that processes cannot be interrupted at the wrong time and employees are protected from fire hazards or chemicals. The flexLock only unlocks once the machine enters a safe state.
By combining these sensors with intelligent control systems, we create an environment in which machines and humans can work together safely and efficiently. In this way, we are contributing to an overall safer and more productive work environment.
What safety challenges have your customers experienced?
Cox: Our customers have experienced a variety of safety challenges in the past when implementing comprehensive safety measures. Often risk evaluations and safety concepts were not carried out completely or were not done at all, which led to uncertainties and potential hazards in the production processes.
Another important aspect is the adaptation of existing production lines to new safety standards. Older plants need to be modernized to meet the current requirements. This requires careful planning and implementation of new technologies while minimizing the impact on the existing operation.
With our expertise and advanced solutions, we help our customers carry out these modernizations efficiently and safely. In this way, we not only ensure compliance with the latest safety standards but also improve the total productivity and operational safety. Our customers benefit from a safe work environment and optimized production processes, which in turn leads to higher competitiveness.
A further important aspect of our services is the provision of comprehensive training. These training offerings are not only of crucial importance to battery manufacturers but also machine builders in different regions of the world. We work closely with them to prepare them for meeting the European safety standards and suitably adapting their production processes. In this way, we ensure that our customers worldwide are updated technology- and safety-wise, whether it be for protecting process machines, robot cells or automated guided vehicle systems.
What specific safety measures are particularly important for preventing accidents and injuries when integrating automated guided vehicle (AGV) systems and industrial robot cells in battery production?
Cox: To further increase safety in battery production, it is especially important to observe safety measures when integrating automated guided vehicle (AGV) systems and industrial robot cells. AGVs should be equipped with advanced safety systems that ensure a safe speed and adjustment of the protective fields.
Laser scanners such as the microScan3 or nanoScan3 allow precise monitoring of the environment. Using the associated safety controller and software (e.g. Flexi Soft safety controller or Flexi Mobile), the protective fields and driving behavior of the AGV are optimized to achieve the required safety level (e.g. an automatic slowing of the AGV when approaching people).
Industrial robot cells should be equipped with suitable protective devices. Standard muting systems use light curtains with muting sensors that detect when an AGV passes the robot cell and enable the AGV to drive through without interrupting production.
When a person attempts to pass through the muting sensors, however, the robot is immediately brought to a safe stop. All swing doors and access points should be equipped with safety switches such as the STR to detect possible human access. For more flexibility of the AGVs around the robot station, it is possible to dispense with some barriers and swing doors by employing a smart safety system, e.g., SICK sBot Speed or the Safe Portal solution.
The optimal combination of measures can ensure a high level of safety in battery production, which maximizes not only the efficiency of production but also the protection of the employees.
What steps were involved in this implementation and how does SICK help overcome these?
Cox: The implementation involved several important steps to improve the safety standards in the production processes. First, we carried out a thorough risk evaluation to identify potential hazards. Then we developed tailored safety concepts and installed the necessary safety components to protect the production lines.
A concrete example is the use of the STR1 safety switch to protect the doors of a machine. This switch ensures that the machine stops immediately when a door is opened. This protects the employees from injury while at the same minimizing downtimes. For machines that stop more slowly, we used flexLock interlock devices. These devices ensure that the machine comes to a complete standstill before an operator reaches the hazardous point.
These measures contribute to ensuring the safety of employees and increase the efficiency of the production processes. By using state-of-the-art technologies and tailored safety solutions, battery manufacturers can optimally protect their production lines while at the same increasing their productivity.
How does SICK keep up to date with the changing safety standards and regulations in the battery industry?
Cox: Our experts are actively involved in the relevant standards committees and international organizations. In this way, we ensure that we are always up to date with the latest safety standards and regulations, including the new Machinery Regulation (EU) 2023/1230. This enables us to respond early to changes and offer our customers the best possible safety solutions. Our comprehensive training offerings and consulting services help companies successfully implement the new requirements of the machinery regulation and design their machines to be safe and compliant.
How does SICK help companies achieve the right balance between the cost of safety measures and the advantages?
Cox: For battery manufacturers it is especially important to ensure safety in all stages of production because the materials and processes are often associated with high risks. By accurately assessing the risks we can install precisely tailored safety solutions that not only increase safety but also improve the efficiency of the production processes. In this way, we help our customers to create a safe work environment while at the same time optimizing the operating costs.
What future trends do you see in safety and battery production?
Cox: In future, it will become increasingly important to record and analyze real-time data on the status of the production equipment. Our sensors deliver exactly this data and thus allow continuous monitoring. They deliver detailed information that makes it possible to immediately recognize and respond to potential safety risks. This significantly increases the safety of the entire production line.
Another important trend is the integration of safety solutions into networked systems. By seamlessly integrating our technologies into existing production systems, we create a holistic safety environment that covers all aspects of battery production. This improves transparency and increases the level of safety as potential hazards can be detected and rectified early.
