Safety in Automated Warehouses: How to Mitigate Risks

Electrical shocks, mechanical impacts, radiation, and fire are risks that automated warehouses face just as much as manual ones. However, effective strategies exist to manage these hazards. At Exotec, we approach this with a ‘safety first’ mindset, beginning with our system designs. Here’s an overview of these risks and their solutions.

What are the five primary risks associated with warehouse operations, particularly those involving automated systems?

• Fire: Electrical faults or the storage of flammable materials can lead to outbreaks of fire in the warehouse.
• Electrical Shock: In an automated warehouse, it is crucial to manage the electrification of robots, stations, and electrical cabinets to minimise the risk of electrocution for operators.
• Mechanical Impact: Interactions between humans and robots can result in shocks and collisions, potentially causing significant damage—not only to the robots but also to operators and handling equipment.
• Radiation: Risks are associated with laser beams used for robot movement (which can be harmful to the retina), light spikes, and the Wi-Fi waves that facilitate communication within the system.
• Hearing Damage: The high volume of machinery can lead to hearing impairment.

With an understanding of these risks, how can they be effectively reduced to ensure warehouse security?

At Exotec, safety is paramount. Our design methodologies focus on optimising operators’ working conditions. Let’s delve into some critical aspects.

A Space Designed for Fire Accessibility

The Skypod warehouse automation system primarily utilises high-density storage areas, optimised for both product placement and accessibility.

Our systems are engineered to ensure that both robots and humans can access all fire points seamlessly. Mitigating fire risks is part of a continuous improvement process that Exotec teams diligently pursue, even beyond the design phase.

Good to Know: All our systems comply with FM Global standards, the authority responsible for the approval of fire protection systems. This compliance extends to our subcontractors involved in sprinkler protection, which encompasses the water installations activated during a fire incident.

48-Volt Batteries: Eliminating Electrocution Risks

Our Autonomous Mobile Robots (AMRs) are powered by batteries that require only five minutes of charging per hour. The Skypod robots utilise low-voltage batteries (48 volts), ensuring that the risk of human electrocution is eliminated.

Collision-Proof Robots

In automated warehouses, the synergy between robots and humans is carefully orchestrated to prevent collisions:

• The Skypod system operates within a closed environment: when robots are in operation, areas designated for storing goods are off-limits to operators.
• At picking stations, the speed of robots is limited, and mechanical barriers are in place to prevent collisions.
• During maintenance, robots are halted by Exotec technicians, who are the sole individuals authorised to access the picking robots.

Each robot is equipped with LiDAR technology (Light Detection And Ranging), which employs laser light to monitor the movement and positioning of robots. This level of precision drastically reduces the risk of collisions with other robots.

Limiting Power to Reduce Radiation Risks

As previously mentioned, our robots employ laser technology, specifically class 1 or 2 lasers. Under normal operating conditions, neither the laser beam nor the radiation poses a risk to operators’ retinas. Effective risk management begins with the careful organisation of workflows within the workspace.

To minimise radiation from Wi-Fi, all Exotec devices operate below the thresholds established by the EN 2014/53/EU directive, commonly known as the Radio Equipment Directive (RED).

Strategies to Maintain Noise Levels Below 80 Decibels

With projections indicating that one in four individuals will experience hearing issues by 2050, what measures can be taken to mitigate noise pollution within warehouses? Our engineers have designed picking stations with a clear goal: to achieve a maximum volume of 80 decibels, which falls below the critical threshold of 85 decibels, at which point hearing protection is required.

Would you like to learn more about our safety-first approach? Visit our dedicated page on safety in logistics warehouse.

Do you want to take action? Discover 5 solutions that can be put in place to limit arduous work in the warehouse.