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collate and evaluate
the data generated by
safety switchgear, a task
accomplished with help
of safety-oriented bus
systems such as ASi Safety
at Work. If necessary,
decentralised concepts
can also be realised, such
as on machines built as
modular systems. In that
case, field boxes and
safety installation systems
from Schmersal may be
used to help create the
conditions for quick and easy series connection of safety
switchgear units and for the integration of different and
mixed switch types, such as safety interlocks and safety
systems. This also allows non safety-related diagnostics
signals to be transmitted to a standard PLC via common field
bus interfaces, such as ProfiNet or Ethernet IP.
From the safety door to the cloud
The new Smart Safety Solution even allows diagnostics
information to be transmitted to the cloud via the Protect PSC1
safety control unit or the SD gateway and an edge gateway
for the capture of data such as limit and distance warnings
and operating status information from safety equipment.
There is, therefore, unbroken communication over the entire
automation pyramid. Diagnostics information can then
be displayed on screens and retrieved on devices such as
tablets and smartphones, allowing for remote monitoring of
production processes and predictive maintenance. Common
cloud platforms, such as Microsoft Azure, are used to allow
data to be displayed via dashboards.
In this case too, new-generation safety control units take
on management of increasing complexity in the safety
circuit, with the modular PSC1 safety control unit capable
of evaluating data from various production cells. As such,
multiple robot cells are able to communicate with one another
and exchange safety-related data and error messages. With
this capability, machine builders can now determine which
data to transmit. In the medium term, products produced on
the machines will also be integrated into the data stream as
they carry with them the relevant data like ‘virtual twins’ — a
fundamental element of Industry 4.0. With the cloud-based
Smart Safety Solution, Schmersal has already created the
conditions for this and other similar concepts.
Good communication skills required
These examples demonstrate how the ability of components
to communicate is central to the exchange of data over
different levels. Flexibility is equally important. As such, the
33 | january-february 2019 |
PSC1 allows the safety functions of machines to be modified
to different applications within each modular principle.
Core components are freely programmable compact control
units (PSC1-C-10/100) with I/O expansion modules available
for secure signal processing from different safety switches.
A universal communication interface allows the user to
make simple software-based selections and adjustments of
different field bus protocols. The same hardware also allows
connection to all common field bus systems (PROFINET,
PROFINET PROFIsafe, EtherCAT, EtherCATFSOE, Profibus,
Profibus ProfiSafe and Ethernet IP).
The new opportunities offered by digitisation are also
changing the way in which designers, who are responsible
for selecting the safety systems, work. At Motek 2018,
Schmersal will be unveiling an online planning tool that has
been designed to enable quick and easy configuration of the
modular PSC1 safety control unit. The PSC1 configurator is an
online tool with 24/7 availability. It is both intuitive and easy
to operate and offers designers a robust planning foundation
in just a few minutes. The planning tool automatically selects
the optimal PSC1 safety control unit based on a selection of
safety sensors and safety outputs and indicates the space
that will be occupied by the assembly configuration on the
profile rail. At the same time, the PSC1 configurator also
generates a bill of materials including item names, material
numbers and details of devices. This bill of materials is linked
to Schmersal’s online catalogue, allowing the user to look up
device information as required. The bill of materials can be
exported in Excel or PDF format for direct e-mail attachment
and subsequent quotation.
Interplay between man and robot
And finally a look at the supreme discipline of machine
safety — the interplay between man and robot in a shared
workspace, with no safety fences to separate them.
Something that can only be achieved with a safety-related
control unit that has been configured to ensure that robots
never leaves their work zones and never exceed defined axle
speeds. The Schmersal Group offers robot manufacturers the
functionality of a safety-related control unit for human/robot
cooperation in the form of its Safety Controller product.
Sensor systems are essential whenever there is direct
contact between man and robot, so that collisions can be
detected, and robot movements stopped promptly. Work is
being conducted in close cooperation with the Bonn-Rhein-
Sieg University of Applied Sciences to develop a technically
feasible and economically efficient safety solution to address
precisely this problem. This and the other examples outlined
above demonstrate that machine safety can help to realise
Industry 4.0 concepts while also harmonising occupational
safety and productivity in innovative and complex integrated
systems.
https://www.schmersal.com/home/
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