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FEATURE MACHINE BUILDING, FRAMEWORKS & SAFETY


sponsored by


Feature


The Trident system


intelligent machine safety technology


Thanks to ReeR Safety technology, a manufacturer of multi-level automated


warehouse systems has moved beyond traditional safety components to a fully


integrated, programmable, safety architecture A


s a leader in the design of automated systems for handling and storing hanging garments, folded goods and light-duty


items, OEM Metalprogetti has hundreds of systems commissioned annually worldwide, and has built its reputation on modularity and mechanical reliability. With its systems, however, safety is a core design principle. Take its Trident system as an example.


Trident is a modular, horizontal, carousel system designed for simultaneous picking and replenishment. This consists of stacked carousels equipped with storage baskets that operate independently at each level. The system is designed for maximum


throughput, with multiple independent operating zones, various access points for personnel, and continuous motion. Safety was therefore a significant challenge. The machine needed an approach to safety that could distinguish between a local maintenance intervention and a critical system-wide emergency. To meet the safety requirements, Trident


therefore features: • Physical guarding & monitoring: Transparent sliding doors allow access to carousels, monitored by magnetic safety sensors that trigger stops only on the specific carousel being accessed.


• Zonal protection: Metal access doors between modules use safety switches with separate actuators to trigger a safe stop of all carousels facing that specific corridor.


• Peripheral safety: Perimeter safety ropes monitor for falling products or positioning anomalies.


1 DESIGN SOLUTIONS MAY 2026 4


the cable footprint and cabinet space. Key modules used in the Trident


system include: • MCT2 Interface: Connects remote input modules via the bus, simplifying distributed wiring.


• MOR4 Modules: Specifically manages Safe Torque Off (STO) signals for the motor drives.


• MBEP Module: Provides PROFINET communication with the primary PLC, allowing for real-time diagnostics and pinpointing the exact location of any safety trip. Above each workstation, a dedicated junction


box houses remote I/O modules (including the MI12T8 for short-circuit monitoring), allowing safety signals to be processed locally before being transmitted back to the central controller.


The benefiTs According to the company, the transition to a programmable, distributed safety architecture, has delivered measurable gains across the machine’s lifecycle: • Reduced footprint and costs: By decentralising the I/O, Metalprogetti reduced the size of the electrical cabinets and slashed the time required for onsite wiring and assembly.


• Rapid diagnostics: Through the PROFINET link, operators can immediately identify whether a stop was caused by a deliberate door opening or a fault, drastically reducing downtime.


• Global shutdown: Strategically placed Emergency Stop buttons that enable immediate total system isolation.


inTroducing reer mosaic Tomanage these inputs without the bulk and rigidity of traditional safety relays, Metalprogetti adopted the ReeR Mosaic platform. The architecture is built around two Mosaic M1 controllers housed in the main electrical panel. Operating independently, each controller manages half of the machine, and it utilises the MCT bus to collect safety signals from remote peripherals, significantly reducing


• Design flexibility: The Mosaic platform’s software-based logic allows Metalprogetti to adapt the Trident to different site layouts and bespoke customer requirements without needing to redesign the entire electrical safety circuit. The collaboration between Metalprogetti and


ReeR Safety proves that in the era of Industry 4.0, safety and productivity are no longer at odds. By leveraging the scalability of the Mosaic M1 system, the company created a high-performance warehouse solution where intelligent safety is an integral part of the machine’s value proposition.


PLUS Automation T: 0121 582 2258 sales@PLUSAutomation.co.uk


www.designsolutionsmag.co.uk


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