42 n SMART WAREHOUSES June 2025 www.drivesncontrols.com Smart warehouses: why Safety Ethernet networks are essential As warehouse automation evolves, so too does the complexity of intralogistics environments. Automated storage and retrieval systems (ASRS), mobile shuttles, and robotic transfer units are now common. While these technologies propel gains in speed, space and efficiency, they also introduce new challenges especially around safety and system integration. Today’s smart warehouses are a rich mix of technologies, often combining ASRS installations with robot palletising cells, AGVs (automated guided vehicles), loading and unloading stations, high-speed conveyor systems, and aisle cranes, all working in synchrony. The diversity of equipment and their interactions within tight footprints require safety systems that are as dynamic and connected as the operations themselves. While traditional hardwired safety and mechanical access control systems are reliable, they are rigid and struggle to meet these demands. With equipment in constant motion and layouts evolving rapidly, flexibility and transparency are no longer optional. Traditional systems often lead to fixed designs, slow fault detection, and time-consuming modifications. This is where safety-rated Ethernet networks come into play. Safety meets agility Modern ASRS systems are built for speed and density. Pallet lifts, conveyor interfaces, and shuttle cars, must operate with minimal delay. Yet with more automation comes increased risk: tighter aisles, moving machines, and complex human-machine interactions. Historically, safety functions, such as emergency stops, guard interlocks and scanners, were implemented through dedicated hardwiring. This is effective in static environments, but often limits adaptability and makes fault-finding more difficult. Safety Ethernet networks offer a more agile approach. Protocols such as Profinet with PROFIsafe, EtherNet/IP with CIP Safety, and EtherCat/EtherCat P with FSoE, support safetyrated communications over industrial networks. This reduces wiring, improves diagnostics, and simplifies system integration. A key strength of these networks is their alignment with modern safety standards. For instance, BS EN 528 outlines safety requirements for automated materialhandling systems, including fault response behaviours. Ethernet-based systems are designed with these requirements in mind, helping integrators to meet performance levels such as PL e or SIL 3 more efficiently. Scalability is another major advantage. As operations grow, safety systems must scale too. Ethernet networks support decentralised architectures, allowing devices such as light curtains, interlocks and scanners, to be connected across wide areas with minimal infrastructure. The result: fewer control panels, simpler layouts, and more flexible expansion. Diagnostics and downtime In high-throughput environments, downtime is costly. A key benefit of Ethernet-based safety is the diagnostic insights it provides. Rather than relying on local fault indicators, engineers can access detailed system status through the network, often using the same software platforms that they already use for automation. This visibility speeds up fault resolution and supports predictive maintenance. Early alerts about wear or connectivity issues allow for scheduled intervention rather than reactive shutdowns. Another challenge is managing access to safeguarded zones. Whether it's clearing a jammed shuttle or routine checks, access must be tightly controlled and recorded. Many safety networks now support smart access systems using RFID or digital keys. These allow permissions to be assigned to individuals, ensuring that only authorised staff can enter protected areas. This helps to maintain compliance and improves traceability across teams and shifts. Flexibility across platforms and regions is increasingly important. Multi-protocol support is now common in many safety components, enabling a single system design to work with different PLCs, control architectures, or local standards. This interoperability reduces engineering effort, simplifies sourcing, and ensures safety systems don’t become barriers when scaling or upgrading facilities. Smart warehouses require more than automation; they need an integrated approach to safety that is just as connected and future-ready. At Euchner, we’re seeing customers prioritise networked safety as a way to future-proof their operations. It’s not just about meeting today’s compliance requirements, it’s about having the flexibility to adapt and grow without re-engineering the safety system every time. That’s where Ethernet-based safety really shines. As facilities become more intelligent and interconnected, safety networks are emerging as the foundation for resilient, scalable, and efficient operations, helping intralogistics leaders stay ahead in a rapidly changing landscape. n Traditional approaches to safety do not apply in smart warehouses. Mark Staples, sales manager at Euchner UK, explains why Ethernet safety networks are more agile, reduce wiring, improve diagnostics and simplify system integration. In the complex environments of smart logistics centres, automated equipment, personnel access zones, and integrated safety systems, need to interact in a coordinated way.
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