Power & Control System Engineering
Category 3 Safe Omron AMR Docking Stations
13 conveyor docking stations upgraded to Category 3 so Omron AMRs and team members can safely share the same space.
CLIENT
INDUSTRY
SOLUTION
DURATION
The Challenge
The plant introduced Omron autonomous mobile robots (AMRs) to carry parts between conveyors, palletizers and heat treat across its production lines. Each conveyor docking point was an open opening where an AMR, a lifter and team members all met. A risk assessment found the existing light curtain muting did not meet IEC 62046, and the lifter areas left people exposed. Every docking station had to reach Category 3 (PL d) before the AMR fleet could run, and the work had to fit inside production windows.
Key Requirements
- Bring every AMR docking station to Category 3 (PL d per ISO 13849)
- Replace non-compliant light curtain muting
- Confirm the AMR is present and docked before any transfer
- Guard the lifter and conveyor transfer zones
- Entry OK / entry NG indication for team members
- Install during short production windows
The ICR Solution
ICR designed a standard Category 3 package for AMR docking stations and rolled it out across 13 conveyor docks, including palletizer, inspection, deburr, liner, exit and heat treat conveyors. At each station a Keyence non-contact safety switch on an ICR-built, self-locating swivel mount confirms the AMR is docked, while Keyence safety light curtains guard the transfer opening and the area below the lifter. Physical guarding divides the AMR and palletizer zones. An Omron safety PLC and safety relays tie into each conveyor’s power circuits, the existing PLC programs were updated for the new interlocks and docking handshake, and entry OK/NG lamps tell team members when it is safe to approach.
Equipment & Technology
- Omron safety PLC and G7SA safety relays
- Keyence GL-R safety light curtains
- Keyence GS non-contact safety switches
- ICR-built self-locating sensor swivel mounts
- Interlock brackets and physical guarding
- Entry OK / NG indicator lamps
- Existing conveyor PLCs (program updates)
Scope of Work
- Risk Assessment
- Safety System Proposal
- Mechanical Design
- Fabrication
- Safety Circuit Design
- Safety PLC Programming
- PLC Program Modification
- Installation
- Commissioning and Validation
Results
All 13 docking stations now meet Category 3, so Omron AMRs, lifters and team members share the floor safely. Each transfer only happens with the AMR confirmed in place, the openings are guarded, and team members get a clear go/no-go signal. Because ICR standardized the package, every station installed the same way inside short production windows, keeping the lines running 24/7.