FEATURE
NETWORKED SAFETY DEVICES
EUCHNER examines how Networked Safety Devices are revolutionising modern warehousing
SMARTER SAFETY, GREATER UPTIME I
n today’s high-speed, high-volume warehousing and logistics centres, safety can no longer be treated as a bolt-on. Automated
Storage and Retrieval Systems (AS/RS) – particularly those employing gantry and aisle cranes – now underpin many modern intralogistics operations, offering continuous throughput with minimal human input. But while these systems boost efficiency, they also bring new risks, particularly when short-term interventions by operators are needed within hazardous zones. These fast-moving cranes, governed under EN 528:2021 – Rail dependent storage and retrieval equipment – Safety requirements, can travel at high speeds and with significant force. Their ability to move in unpredictable directions makes them particularly dangerous if a person becomes trapped inside during operation. For managers responsible for operations, maintenance, or health and safety, the question is how to ensure safe access without compromising productivity.
THE SHIFT TO NETWORKED SAFETY Fieldbus-based safety systems are fast becoming the norm in these environments, replacing traditional hardwired architectures with flexible, scalable alternatives. Safety devices connected via industrial Ethernet protocols (such as PROFINET/ProfiSAFE or Ethernet/IP with CIP Safety) allow machine builders and operators to integrate safety directly into the control network – enabling streamlined installation, easier diagnostics, and real-time visibility of system status. Unlike older solutions that relied on custom wiring and standalone panels, these devices offer modular configurations that combine safety and control functions in one unit. This not only
52 DESIGN SOLUTIONS JUNE 2025
reduces cabling but can also eliminate the need for bespoke operator panels. Safety door handles, access authorisation systems and emergency stops can all be networked and monitored centrally – significantly reducing commissioning time and long-term maintenance overheads.
SAFE ACCESS FOR HUMAN INTERVENTIONS One area of particular concern is managing short-term operator interventions in otherwise automated zones. Access control here is about more than stopping the machine: it’s about ensuring the machine can’t restart unexpectedly; and that access is clearly authorised and traceable. A good example of this is the growing adoption
of intelligent RFID-based key systems. These allow authorised personnel to enter a hazardous area by removing a personal coded key from a docking station. The system automatically prevents restart until that specific key is returned – no risk of duplication, no ambiguity about who entered and when. Several manufacturers of gantry and aisle
crane systems have integrated these RFID solutions as a standard safety measure. Compared to older mechanical trapped-key systems, they offer far more flexibility and can be scaled across large facilities with minimal effort.
BETTER VISIBILITY, FEWER SURPRISES Because networked safety devices operate as part of the control system, they provide immediate insight into system status. Open doors, missing keys, inactive sensors – all of this can be flagged instantly to an HMI or SCADA system, allowing maintenance and
operations teams to act before small issues escalate into downtime. This transparency also supports better planning. Safety-related events and trends can be logged, reported, and analysed – helping managers refine access procedures, improve training, or identify areas for improvement.
A SMARTER WAY FORWARD Modern warehouses need safety systems that match their pace. That means flexible architecture, minimal manual intervention, and the ability to adapt to change without tearing out cabling or replacing control panels. For growing or evolving operations, especially those with advanced AS/RS installations, these networked safety solutions can deliver real gains in productivity, availability, and compliance. David Dearden, managing director of EUCHNER (UK), explained: “The pace and scale of automation in logistics means safety systems need to do more than just stop a machine. They have to enable safe, authorised access, track activity, and get operations back up and running quickly. Technologies like RFID-based key systems and modular, networked safety devices are helping logistics operators build resilience without adding complexity.” As the lines between IT, operations and safety
continue to blur in modern logistics, adopting fieldbus-integrated safety technology isn’t just a matter of compliance – it’s a practical step toward smarter, more agile facilities.
EUCHNER (UK) T: 0114 2560123
www.euchner.co.uk
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