⚙️ Safe Automation at SEW-EURODRIVE with Leuze Sensor Technology

[Süeda Asil]

🚀 Production Never Stops at SEW-EURODRIVE​

SEW-EURODRIVE, one of the giants in the world of drive technologies, provides the power of motion in many areas, from airport baggage systems to package sorters in e-commerce logistics centers. Operating with 22,700 employees and 92 assembly plants worldwide, the company continuously invests. Most recently, its smart factory opened in Graben-Neudorf focuses on the production of shafts and gear components. A significant part of this expansion is the fully automated production buffer storage, realized with SIVAplan's intralogistics and Leuze's sensor expertise.

📦 Systematic Buffering​

This logistics module serves as a production buffer between gear and shaft manufacturing and the hardening shop. Michael Schütz (Head of Hardening Shop at SEW-EURODRIVE) states, "The automated warehouse separates the soft machining, hardening, and hard machining processes." Constructed from 70 tons of steel, the warehouse consists of two racks, each over 76 meters long and 9 meters high. With double-deep storage capacity, it has a total of 2,300 storage locations. Between the two racks, two fully automated stacker cranes operate on a single traverse axis. Christian Langsdorf, Sales Manager at SIVAplan, adds, "The stacker cranes transport special hardening racks from production to the furnace system." Each rack, including materials, can weigh up to 510 kilograms.

🤖 Clear Path for Mobile Robots​

SIVAplan implemented this logistics module and its high-level control system as the general contractor, together with PROCAM Steuerungstechnik GmbH. The system communicates with all subordinate machines, systems, and vehicles, operating in integration with the high-level ERP system (SAP). Leuze sensor technology is a critical component of this system. Christian Langsdorf says, "SIVAplan's solutions and Leuze's sensor expertise complement each other perfectly." Mobile robots safely access material transfer stations thanks to Leuze's RSL 400 safety laser scanners. These scanners create a vertical protective field, ensuring the safe passage of robots. Thanks to the integrated PROFIsafe/PROFINET interface, the RSL 400's integration into the safety control system is very easy.

📏 In-Process Contour Control​

After the loaded racks are transferred by the AGV, they are moved via a conveyor system to a contour control station. Leuze HT25C diffuse sensors detect the racks, while CML 720i measuring light curtains determine the outer contours of passing objects. Frank Wüster (Leuze Sales Manager) explains, "The diffuse sensors, which ignore high-visibility vests, prevent false detections." This station also features Leuze's industrial IP cameras.

🛡️ Safe Loading and Unloading​

At each material transfer station, a manual workstation has been integrated to allow SEW-EURODRIVE employees to manually unload and inspect racks. MLC 530-SPG safety light curtains ensure that racks are always loaded and unloaded safely. Thanks to the patented Smart Process Gating (SPG) technology, no additional muting sensors are required, which allows for a more compact system design. These Type 4 MLC 530-SPGs meet the highest safety requirements in accordance with EN IEC 61496 and achieve performance levels PL e and SIL 3.