Sensors & transducers
SICK TECHNOLOGY UNDERPINS MAJOR SAFETY SYSTEM PROJECT
The flexibility, span and ease of use of SICK’s Flexi Soft Controller helped Safety Systems Technology create a unified safety solution across an entire steel welding facility.
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ensor specialist SICK supplied bespoke machinery safety solutions company Safety Systems Technology with their Flexi Soft programmable modular safety controller to create one of the largest span configurable safety projects in the UK. Installed as part of a unified safety system, Flexi Soft from SICK ensures that each component in a network of safety controllers communicates effectively across a facility that welds large sections of steel together to enhance safety and visibility.
CREATING A COMPLETE SAFETY SOLUTION REQUIRES A CONFIGURABLE NETWORK OF CONTROLLERS Following an incident at a steel processing facility where sections of steel are welded into continuous sections, Safety Systems Technology were called in to assist with additional protective measures. Safety Systems Technology developed and supplied a complete safety solution across the site, replacing a previous system comprising standalone safety concepts on some machines facilitating rope switches on conveyors. The customer wanted a solution to provide an immediate safe ‘Global’ Emergency Stop to prevent future incidents and enhance safety and visibility on site.
Safety Systems Technology developed a single unified safety solution linking up machines and conveyors. The size and scale of the plant, to support large sections
of steel profile, means conveyors are very long, with significant distances between local safety concepts. As part of the project to enhance safety throughout the plant, Safety Systems Technology looked at the potential to create a configurable safety network of controllers.
FLEXI SOFT SENSOR INTELLIGENCE FROM SICK DELIVERS LARGE SPAN CONFIGURABLE SAFETY
Having worked with intelligent sensor specialist SICK for many years, Safety Systems Technology selected the SICK Flexi Soft Solution to ensure that controllers communicate safely and effectively across large distances. Creating the largest span project in the UK, Safety Systems Technology used SICK Flexi Soft to daisy-chain field devices via Flexi Line, creating a unified safety system throughout the plant. As part of the safety upgrade works, a network of local control panels located around the facility creates four zones of operation. These are connected to a new panel installed in the main Welding House to facilitate a site-wide ‘Global’ Emergency Stop function and Global Reset. This allows for the entire facility to be put into a safe state in the event of a hazardous situation. An overview of the whole system is displayed via a PLC on HMIs in real-time, supporting ease-of-use and transparency.
EASY INSTALLATION AND COMMISSIONING MADE FLEXI SOFT SETUP SIMPLE
SICK Flexi Soft modular safety controllers can be easily installed and programmed via intuitive, license-free Flexi Soft Designer configuration software. The controllers are networked together over a SICK Flexi Line Interface network to provide an expandable and configurable safety system capable of addressing all required safety functions
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and future safety requirements, with continuous diagnostics down to the automation level. Capable of achieving Performance Level E (the highest performance level) in accordance with EN ISO 13849-1, the SICK Flexi Soft range allows for safe series connection and the local modular hardware platform allows the creation of tailored and efficient solutions for many different applications. SICK has a wide range of Flexi Soft modules available, all of which are easy to program, commission, and can provide continuous diagnostics via any fieldbus. Commenting on the project, Wayne Morrison, SICK UK technology sales engineer, says, “We were pleased to continue our strong relationship with Safety Systems Technology and be part of such a large and important project. It demonstrates the extensive capabilities and range of SICK Flexi Soft modular safety controllers, Flexi Soft Designer configuration software and the Flexi Line Interface network. SICK Flexi Soft solutions provide a unified safety solution and peace of mind across industrial settings, including large-scale outdoor applications such as ports and construction sites.” Allan Harris, director of Safety Systems Technology, adds, “SICK’s technology helped us successfully create a much safer system at this site. Having completed this project successfully, we now have a strong, ongoing relationship with the customer. We have worked with SICK Sensor Intelligence for many years, as we have evolved from a reseller of safety products to a designer and integrator of safety solutions and risk assessments. I find SICK UK always has the products we need available and a strong working knowledge of our industry. In fact, SICK’s configurable relays are our go-to product when flexibility is required.”
SICK
www.sick.com May 2026 Instrumentation Monthly
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