Pilz delivers compliant access management system at Schüco's testing facility

When constructing its new component testing laboratory, Schüco — a German provider of building envelopes — seized the opportunity to implement a forward-thinking safety and security concept.

Schüco envisioned a centralised permissions management system that would streamline access control and safety infrastructure. The goal: a unified solution that clearly defines who can access each test bench, while granting operating permissions based on individual qualifications and personal profiles.

Balancing safety, compliance, and operational demands

The new test centre introduced a diverse range of machines and procedures, each with distinct operational risks. To manage these effectively, the safety system needed to be centralised and scalable — capable of assigning personalised, qualification-based permissions while adapting to the specific safety requirements of each test bench. Importantly, it also had to comply with the latest standards set out in EC Directive 2006/42/EC.

Uniform safety for all test benches

To meet these challenges, Schüco partnered with Pilz, a trusted automation expert, to implement a comprehensive safety and access management system. That vision Shüco had is now realised through an integrated safety solution that safeguards personnel from potential hazards, minimises operational errors and unauthorised interventions, and helps reduce plant downtime. At the core of the solution is PITmode flex, an RFID-based operating mode selection and access permission system, supported by the PNOZmulti modular safety controller. This setup allows for everything from basic user authentication to complex permission matrices tailored to individual roles and tasks. Pilz worked closely with Schüco to develop a unified safety concept that could be customised for each test bench, which simulates stress conditions such as mechanical pressure, elasticity, and extreme temperatures. While the protection principle remains consistent across all systems, it is adapted to the specific risks of each bench.

The system now operates with three distinct permission levels. Level 1 allows access only when machines are stopped, suitable for cleaning or maintenance. Level 2 grants limited operational access for inspections and low-speed mechanical tasks. Level 3 provides full control, including access to sensitive data parameters.

This streamlined approach was achieved using the PITmode flex operating mode selection and access permission system, with each operator’s access rights stored on an RFID transponder for secure and personalised authorisation. PSENslock safety locking devices and PSENmag non-contact magnetic safety switches are used to secure the gates, while the PNOZmulti modular small controller serves as the higher-level control instance. Together, this holistic safety concept ensures that testing processes run smoothly, with enhanced protection, reduced risk of error, and improved operational efficiency.

Schüco’s upgraded test benches are now fully operational, compliant, and future-ready. The system has not only enhanced safety and control but also simplified workflows for operators. Looking ahead, Schüco plans to extend the system to its training workshop, where graduated access levels will help apprentices safely interact with electrical systems based on their experience level.

“Pilz provided an exemplary overall solution combining Safety and Security, which we can tailor to our needs and use on all test benches,” said Michael Bohle, Team Lead Electrical Engineering and Calibration, Schüco Technology Center. “With commitment, high levels of expertise and the necessary components, Pilz has taken us a big step forward.”