He has extensive experience in manufacturing protection devices for Bucher relays for transformers, monitoring relays for step switches and other liquid cooling isolation devices. Barreben worked closely with the University of Magdeburg to develop a prototype of an uninterruptible power supply based on fuel cell technology. As a batch prototype, it is intended to power signal systems, lighting equipment, radio poles, telecommunications distributors, and other off-grid power users. Depending on the desired output, the unit can also be used as a redundant emergency power unit to respond immediately when power is lost. Compared to solar-based systems, this modern generator does not require an expensive backup battery and can be used almost all the time. In the higher output section, it can replace high maintenance, non-environmental diesel generators.
The cabinet is weatherproof and looks unremarkable: it occupies less than a square meter and is about the size of a telephone distribution cabinet that can be seen everywhere on the street. The enclosure is similar to a switchgear and there is no indication that it contains a variety of high-tech equipment. There is a generator based on modern fuel cells in the tank.
Expertise and advice for identifying risksThe compact power supply consists of two parts: the main chamber is equipped with a fuel cell module, a process control system and all electronics, while the secondary chamber consists of four pressure vessels filled with hydrogen. The current module is free to choose the output voltage and is powered for 1-10 kW for 10 hours, making the prototype suitable for power supply in the low load range.
Used in downtown civilian areas or off-grid applications, the main room on the left and the fuel room on the right
Obviously, this innovative product needs to meet the requirements of the German Product Safety Law and relevant European standards and directives as early as the development stage. Risks should first be determined in accordance with EN ISO 12100 to minimize potential hazards to people and the environment. Barreben seeks help from recognized experts. “We have learned that Pilz is an experienced supplier of automation and safety solutions, and its application is beyond the scope of traditional mechanical engineering. In addition to the technology and the complete set of services it provides, Pilz is specialized in machine and equipment safety. Knowledge and harmonized standards are key factors in making this choice,†said Sascha Hanf, a project developer at Barreben.
Clear, secure and easy to use solutionAfter initial consultations, Barreben and Pilz identified areas where security measures were required. For example, precautions must be taken to prevent the two doors from being opened unintentionally or intentionally. Authorized personnel must not be exposed to any hazards when replacing pressure vessels or performing necessary maintenance work. The programmable safety system is used not only to monitor safety signals, but also to connect process control systems, external sensors and remote maintenance. Occasionally the enclosure will be unprotected, so a tamper-proof enclosure is required.
“We worked with Barreben to analyze potential risks and recommend possible solutions and appropriate hardware and software components. It is important to always have a clear, easy-to-use solution that eliminates possible misuse from the start,†Peel MarTIn Mielke, an application engineer in the magnetic field staff, stressed.
PSENmag monitors the door, PITmode controls accessPellmag's two magnetic door switches PSENmag monitor the door. If the door is opened without access authorization, the system will enter safe operation mode. Pellson's non-contact safety door system PSENslock provides additional protection, combining reliable safety door monitoring with powerful non-contact magnetic interlocking in a single unit. This will meet the highest safety requirements while being able to conditionally withstand vandalism.
The operating mode selector switch PITmode is used to ensure that the service personnel can easily and risk-freely replace the pressure vessel or carry out maintenance work: the smart RFID access key determines the security status that the system will enter after its insertion, the authorization obtained by the owner of the key, and the permission Or do not allow the key owner to take action on the device. Before replacing the pressure vessel, the service company employee must first authorize the personal key. After the system enters safe mode, the pressure vessel can be replaced without risk. Once the door is closed, the system automatically returns to operating mode.
PITmode: Clear and operational protectionThe operating mode selector switch PITmode provides two functions in a compact unit: selection of the operating mode and access control of the machine.
The same applies to service engineers: the installed emergency stop button ensures rapid downtime in emergency situations, allowing service engineers to perform maintenance without risk. Two operating modes (normal and maintenance mode) are defined in the PITmode of the current prototype of Barreben. Up to 5 operating modes can be implemented if necessary. It is also planned to introduce remote maintenance functions to allow staff to register with the system prior to maintenance.
“What makes us happy is that everything is so simple and straightforward, no one will worry about health when working on a prototype,†Sascha Hanf stressed.
PNOZmulTI 2 focuses on safety signalsThe configurable control system PNOZmulTI 2 is only 45 mm wide, but is suitable for performing several safety functions on a device or machine. System expansion is possible through other modules. PNOZmulTI 2 can be connected to a public communication network. The security architecture can be created without regard to the superior control system.
The safety signal and emergency stop button of the control system PNOZmulti 2 can be configured. The device has 20 safety inputs, of which up to 8 can be configured as signal outputs and 4 can be configured as safety semiconductor outputs. The PNOZmulti Configurator makes it easy to configure with mouse drag and drop. The base unit is 45 mm wide and can be flexibly and economically expanded from three safety functions at any time. The CANopen interface allows the PNOZmulti 2 to be connected to device control systems and external sensors such as monitoring internal or temperature.
Performance level d securityPilz's PAScal safety calculator calculates the performance level (PL) d of EN ISO 13849, and all components used by Pilz meet or exceed the requirements of this class. “Pilco offers safety components and consulting services to get the job done. Our staff can safely and easily use the implemented solutions. In the development of this series of products and the upcoming CE certification process, Pilz offers us Great support," concluded Sascha Hanf.
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