Системы управления промышленной безопасностью от SICK

Системы управления промышленной безопасностью от SICK
P R O D U C T S & A P P L I C AT I O N S
Integrated solutions
can also be simple
sens:Control — safe control solutions
safetyPLUS® — we solve
safety problems
Safety solutions from SICK increase your security of investment,
open up new potential for savings due to more efficient processes,
and always remain focused on the primary objective — the safety of
man and machine.
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Rock-solid safety concepts for perfect
operational safety
Water-tight system solutions for complete
safety applications
safetyPLUS® provides a unique range of competencies for the safety of man and machine. After
all SICK is the world’s leading manufacturer of
industrial safety systems and convinces with an
impressive combination of competence, products and services.
Behind safetyPLUS® is the world’s most versatile product portfolio: A comprehensive safety
package from safety switches through optoelectronic sensors to safe control solutions and
networks. Simple and trouble-free in application
from planning to worldwide usage.
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Unlimited potential for savings due to
integrated safety concepts
The unique cost-effectiveness of safetyPLUS®
saves time and money! This starts with the
uncomplicated planning and carries on through
installation and commissioning to the actual
production. Every SICK technology is as easy as
possible to use and will also be up to date in
five years time.
Complete safety by means of services
for every day
The safetyPLUS® services: SICK experts advise
and assist from the first plant walk-through,
during the risk assessment and all the way to
the CE assessment — always compliant with
the latest standards and directives, and with
the SICK inspection seal for machinery and
systems.
By the way: Every year SICK performs more
than 10,000 safety inspections worldwide.
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Further informations:
Product information
Data sheet
www.sick.com
Service you can depend on
With SICK you will always obtain optimal results in the
interaction between man and machine.
With SICK you have, in this sensitive area, a partner at your side whose innovations
have been setting international standards for more than 60 years; most recently with
safetyPLUS®, the all-round package for industrial safety.
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P R O D U C T S & A P P L I C AT I O N S — S A F E C O N T R O L S O L U T I O N S | S I C K
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sens:Control — safe control solutions
Page
Overview
safetyPLUS® —
we solve safety problems
sens:Control — safe control solutions
Your advantages
sens:Control — safe control solutions
Safety relays overview
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Application-orientated specialists
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The all-rounder, a relay for all sensors
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Safety controllers overview
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Flexi Classic
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Flexi Soft
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Network solutions overview
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DeviceNet Safety
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EFI gateways
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International Service Solutions
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Compliance & Design
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Product support
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Training & Education
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Services
Verification & Measurements
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Upgrade services
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Applications in detail
Straightforward automatic hazardous
area protection on a palletizer station
Integration of a safety light curtain in the
emergency stop circuit on a press
Safety automation on a wrap-around tray
packaging machine
Hazardous area and access protection on
a robot cell
Hazardous point protection for material
feed on a rotary table
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Product selection
sens:Control — safe control solutions
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More safety due to customised service!
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Your advantages — explained simply
sens:Control — a new name for safe
control solutions
The new generation of safe control solutions
from SICK combines advanced technologies with
ease of use in every project phase. How does
it work? Very simply: SICK developed, from the
ground up, a new integrated product concept
that was consistently designed for uncomplicated
usage.
A comprehensive range of engineering and services
Sometimes it is a long way from planning to
reality — but not with SICK! With sens:Control
the selection is quick and the configuration simple. In all phases of the project from planning,
through commissioning to maintenance and
upgrades to existing systems, we support you
with comprehensive services.
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Overview
Products
Services & Support
Applications in detail
Product selection
safety + simplicity
sens:Control — safe control solutions
Application-orientated and platform independent, the safe
control solutions with optimal sensor integration.
sens:Control — the advantages:
• Simple selection, uncomplicated engineering
• Easy configuration, low integration effort
• Open for all automation environments
• The right solution for every application, from the relay
through the modular controller to networked systems
Simple, quick commissioning
Platform independent integration
• Either:
Configuration using intuitive user software
• In standard networks
• Or:
Configuration via screwdriver
• In safe networks
Modular and adaptable
Fast Shut-off
• Flexible number of
inputs/outputs
• From simple to complex
logic
• Modular expandability
• Fast shut-off times reduce the safety
distances and provide optimal protection
for man and machine
Very easy unit exchange
• Captive Flexi-Soft system plug for the
complete configuration. Cannot be mixed up,
as connected to the machine
Optimal sensor integration
• More functionality due to EFI
• More information on page 9
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The optimal solution for every application
sens:Control — safe control solutions for a wide range of sectors
safety + simplicity must be the solution for all sectors and
applications.
The range stretches from the simple integration of an
emergency stop pushbutton, through the connection
of safety switches with emergency stop, e.g. to packing machines, the combination of optical safety sensors
with machine contacts on a press, or the combination
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of entry/exit stations with access protection in logistics, to
the networking of complex systems or linking of modular
machines:
sens:Control provides the right solution for all applications
and sectors and that with minimum engineering effort.
Safety relays
Safety controllers
Network solutions
The complete range makes it possible to integrate all safety components
into a machine or system. The safety
relays are very reliable and robust
and impress with their quick mounting using interchangeable removable
terminals.
Safety controllers can also be simple. Flexi is an open and modularly
expandable system for the convenient connection and the intuitive configuration of safety solutions.
For machines and systems with a
high degree of connectivity. These
solutions permit the integration and
evaluation of all safety sensors in all
common fieldbuses up to complete
safety automation with controllers
and remote I/Os.
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Overview
Products
Services & Support
Applications in detail
Product selection
Optimal sensor integration
The SICK-specific EFI (EFI = Enhanced Function Interface)
is a safe communication interface between SICK devices.
Using this EFI, process data from several users can be
transferred bi-directionally with little installation effort and
diagnostics can also be performed.
The major advantage of the EFI compared to integration
using OSSDs (Output Signal Switching Device) is that
diagnostic information from all EFI users with a large
amount of data is available to the higher level controller
or gateway.
Integration via EFI
In the case of integration via OSSDs, it is only possible to
perform local diagnostics directly at the device. There is
no bi-directional communication between the individual
users via OSSD signals.
EFI provides a quick overview of the entire system configuration, which means increased capacity to act and
therefore increased availability of your machine.
Expanded sensor functionality means, e.g.:
• Simultaneous protective field evaluation
(S3000 safety laser scanner)
• Protective field switching
• Operating mode switching
• Sampling of status signals
(e.g. contamination of the front screen)
Integration via OSSD
For diagnostics and to achieve the fastest response
times, with SICK it is possible to connect the sensors
to the safety controller using the interaction of EFI and
OSSDs. By means of this optimal connection of EFI and
OSSDs, the EFI users can communicate with each other
and the machine can be quickly switched to a safe state.
Optimal connection of OSSD and EFI
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Simplicity in the foreground
Safety relays
The safety sensors encompass a large range of products,
from the single-channel emergency stop pushbutton to
the safety laser scanner with PNP outputs. Additionally,
there is the need for manual or automatic reset and application-related logic such as muting and safety locking.
The SICK relay family encompasses 14 different variants
with the objective of being able to connect all types of
sensors; the right relay for all your requirements.
• Simple integration of all safety components
• Compact devices: up to 4 safety contacts
in a 22.5 mm housing
• Reliable and robust
• Numerous connection diagrams online
• Fast mounting due to removable terminals
All products are approved:
• up to category 4 according to
EN 954-1 or
• for applications up to Performance Level e according to
ISO 13849-1 and
• up to SIL3 according to
IEC 62061
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Overview
Products
Services & Support
Applications in detail
Product selection
Integration of single-channel sensors and OSSDs:
Application-orientated
relay:
Universal relay:
Optical safety devices have OSSD
outputs that only need a simple
relay. The UE10 series and the UE12
series are particularly suitable for
these sensors. If more outputs are
required, you can use the cascading
function. The UE23 family is also
suitable for this function; with its simplicity this family is aimed particularly
at single-channel sensors.
Special applications require specific
relays. For example in the case of a
two-hand control panel, you can use
the UE42-2HD. This and other applications can be solved without problems by using a special relay.
Relays for special applications are:
• UE42-2HD: for two-hand control
panels
• UE44-3SL: for safety locking device
• UE45-3S1: for stop category 1
• UE49: the muting specialist
The majority of machines are only
protected using safety switches.
This is the application area for which
the UE43 family is intended. Simply
select the type of voltage supply,
the type of reset and the number of
outputs and you are already done.
For more versatile usage, the UE48
family has additional features, for
example the control of pressure
sensitive mats; simply universal!
Applications:
• Storage and conveyor technology
• Packaging
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Applications:
• Presses
• Logistics
Applications:
• Robots
• Electronics
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Shut off simply
Application-orientated specialists
For example UE42-2HD
Product description
Customer benefits
• Specially designed for a two-hand
control panel
• Integrated external device
monitoring (EDM)
• Complies with EN 574 for type
III C devices
• Low control cabinet space
requirement
• 2 N/O contacts and
1 N/C contact
... and the all-rounder, a relay for all sensors
UE48-2OS, UE48-3OS
Product description
Customer benefits
• For emergency stop pushbuttons,
safety switches, safety light curtains and safety laser scanners
• Low stockholding due to reduction in number of variants
• 3 N/O contacts and 1 N/C contact or 4 N/O contacts
• Automatic or manual reset
• Integrated external device
monitoring (EDM)
• Rapid commissioning due to
removable terminals
• Low control cabinet space
requirement
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Overview
Products
Services & Support
Applications in detail
Product selection
Normally open/
normally closed
Dual-Channel Input
Dual-Channel Input
Dual-Channel Input
Dual-Channel Input
Dual-Channel Input
Muting-Sensor
technology
1)
Safety switches with mechanical locking
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Safety controllers can also be simple
Safety controllers
Openness, scaleabilty and modular
expandability are customer requirements that SICK solves with the
flexible sens:Control — safe control
solutions.
In the foreground here are very
simple operation and optimal integration of all safety components to
solve integrated safety applications.
Depending on customer requirements, products are available in compact designs or modularly expandable up to IP-67 variants.
All products are approved:
• up to category 4 according to
EN 954-1 or
• for applications up to Performance
Level e according to ISO 13849-1
and
• up to SIL3 according to IEC 62061
The simplest:
Flexi Classic
• Automate simply
• Configuration via screwdriver
Applications:
• Storage and conveyor technology
• Packaging industry
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Overview
Products
Services & Support
Applications in detail
Product selection
The smallest softwarebased: Flexi Soft
Unique in IP 67: UE4427,
UE4457
The most compact with
network master: UE4470
• Integrate conveniently
• Modular multitalent with intuitive
configuration software
• Fully automate with safety remote
controllers
• Makes possible usage directly on
the machine
• Flexible safety controller
• Safe networking of machines
Applications:
• Automated guided systems
• Robots
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Applications:
• Muting stations
• Rotary table applications
Applications:
• Linked systems
• Robots
• Handling systems
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Safety controller without software
Flexi Classic
An overview
Direct sensor operation and additional fully integrated logic saves time
when designing the circuit diagram
and installing the wiring.
Adjustment using a screwdriver
saves the need for a computer during
commissioning and maintenance of
the system.
Product description
Customer benefits
• Can be configured on the front of
the device using a screwdriver
• Optimal graduations prevent
superfluous inputs and outputs
• Direct wiring with every type of
sensor
• Freely selectable outputs by
means of modules with transistor
outputs and relay contacts
• Logical operators (And/Or/Muting/Bypass/Reset/External device
monitoring)
• Configuration and device
replacement via screwdriver
• The controller grows with the application
• Integration in all leading networks: CANopen, PROFIBUS-DP,
DeviceNet, Ethernet TCP/IP,
Ethernet IP, Modbus TCP
Development on the
desk, installation on site,
diagnostics anywhere
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Overview
Products
Services & Support
Applications in detail
Product selection
Powerful logic with the simplicity of a screwdriver
Flexi Classic is a modular system on which the related
logic functions (And/Or/Muting/Bypass) are defined using
a rotary switch.
Flexi Classic can operate with all types of sensors, e.g.
light curtains, laser scanners, emergency stop pushbuttons, mechanical and electrosensitive switches and much
more.
Each logic module provides 8 I/O and up to 9 different
programs. All these simple features, once connected
together, make it possible to solve a very wide variety of
applications even without software.
Configuration: the software can help!
The Flexi-Classic configurator is an immense help in
preparing a Flexi system. You can place modules side by
side; adding sensors and actuators using drag-and-drop
and the view of the internal logic make design quick and
easy.
You will find the configurator at: www.sens-control.com
The muting expert:
The Flexi Classic can, as one of its possible uses, solve
muting applications. Modules specially designed for muting are available for more complex applications. They
provide a complex range of functions that meet every
requirement, for example direction monitoring, sequence
monitoring, override etc.
Possible uses for the diagnostics
Status and diagnostic information is made available via
gateways over all leading fieldbuses, such as CANopen,
PROFIBUS-DP, DeviceNet, Ethernet TCP/IP, Ethernet IP
and Modbus TCP.
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Simplest answer to demanding
machine requirements
Flexi Soft
Versatility re-defined
The Flexi Soft modular safety controller provides function modules that
can be flexibly combined, is of compact design in any final configuration,
has software-based logic functions
and expanded features for fieldbus
integration.
Flexi Soft is suitable for the control
and monitoring of a large number
of tactile and electrosensitive safety
sensors, e.g. guard switches, emergency stop devices, light curtains or
laser scanners.
The system is designed for the combination of 12 Flexi Soft modules.
Available are an I/O expansion module with eight inputs and outputs, a
pure input expansion unit with eight
inputs, two relay modules as well
as gateways for integration in all
leading fieldbuses. On the usage of
intelligent safety sensors, a safety
controller variant with EFI (Enhanced
Function Interface) is available.
Product description
Customer benefits
• Shortened response time and
therefore shorter distance from
the hazardous point due to fast
shut-off favours the construction
of smaller machines
• Graduations prevent superfluous
inputs and outputs
• Configuration via intuitive
software with a graphical user
interface
• Function block based logic editor
with comprehensive library of
certified function blocks
• Configuration memory in the system plug for rapid commissioning
• Intuitive software with tabular
wiring plan
• Expanded sensor functionality
via EFI
• Optimised integration via EFI
(e.g. S3000, C4000)
• Integration in all leading networks: CANopen, PROFIBUS-DP,
DeviceNet, Ethernet IP, Ethernet
TCP/IP, Modbus TCP
Modular multitalent
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Overview
Products
Services & Support
Applications in detail
Product selection
Simple and individual:
The Flexi Soft is a powerful, modular, software-based
safety controller that can be efficiently adapted to the
requirements of a variety of safety applications due to its
scaleability.
Intuitive: Hardware configuration via software interface
After the selection of the Flexi Soft modules to be used,
all the necessary sensors and actuators can be "wired"
simply using the drag-and-drop principle, and parameters
configured. The inputs and outputs defined are then available in the logic editor, which includes more than 30 different logic and application-specific function blocks.
You can download the Flexi Soft Designer free of charge
at: www.sens-control.com
Commissioning via system plug
Writing the configuration to the separate system plug
moves the programming to the office and for commissioning it is only necessary to connect the system plug at the
production line. As the voltage supply is also provided via
this plug at the same time, a system plug can be changed
at any time without any wiring effort. This feature makes a
laptop on site unnecessary.
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Even distributed machines and systems
can be easily automated
Network solutions
A distributed system is the best
choice if maximum flexibility with
minimum overall costs is required.
Today remote solutions must be
openly scaleable and modularly
expandable.
Modern software tools support the
designer during the optimisation of
the system performance.
All products are approved:
• up to category 4 according to
EN 954-1 or
• for applications up to Performance
Level e according to ISO 13849-1
and
• up to SIL3 according to IEC 62061
Network solutions from SICK permit
the integration and evaluation of all
safety sensors in all common bus
systems, all the way to complete
safety automation with programmable controllers and remote I/Os.
Optimal remote functionality and convenient diagnostics for fast troubleshooting are a matter of course.
Automate simply:
AS-Interface Safety at Work
• Complete safety automation with
AS-i monitor and slaves
• Bus nodes in IP 65 and IP 67 for
simple safety automation without
the need for a control cabinet
Applications:
• Storage and conveyor technology
• Packaging industry
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Overview
Products
Services & Support
Applications in detail
Product selection
Integrate conveniently:
PROFIsafe
Complete automation:
DeviceNet Safety
Use more functionality:
EFI gateways
• Optimal integration and preevaluation of all safety sensors on
PROFIsafe
• Convenient diagnostics for fast
troubleshooting
• Minimisation of the number of users in the network due to intelligent
bundling directly in the field
• Complete safety solution with compact controller and remote I/Os
• Open safety automation based on
globally accepted standard
• Convenient, uniform diagnostics for
fast troubleshooting
• Remote controller in IP 67 for
safety automation directly on site
without the need for a control
cabinet
• Optimal utilisation of the convenient sensor functionality from SICK
now available in all leading network
standards
• Convenient, uniform diagnostics
on the sensors for fast troubleshooting
Applications:
• Assembly systems
• Automotive industry
8010737/2008-11-19
Applications:
• Robots
• Handling systems
Applications:
• Automotive industry
• Machine tools
S I C K | P R O D U C T S & A P P L I C AT I O N S — S A F E C O N T R O L S O L U T I O N S
21
Simple — flexible — networked
DeviceNet Safety
Remotely automate conveniently
Product description
Customer benefits
• Safety automation system with network support
• Complete safety automation for uniform solution from
a single source
• Uniform graphical user interface for the configuration
of the system and the devices right down to the sensor
• Comprehensive library of certified function blocks for
evaluation and logic available
• Best possible overall solution, as sensors and
controller are optimally matched
• Usage of an open and internationally recognised
network standard
• Unique — distributed intelligence can be easily realised with a remote controller in enclosure rating IP 67
• Unmatched fast, constant system response times,
independent of the network load due to Fast Shut-off
The complete solution — everything
from a single source
22
P R O D U C T S & A P P L I C AT I O N S — S A F E C O N T R O L S O L U T I O N S | S I C K
8010737/2008-11-19
Overview
Products
Services & Support
Applications in detail
Product selection
UE4470: The compact central unit
• Flexible safety controller with comprehensive libraries of
certified function blocks
• Pre-configured functions for the quick realisation of the
application, e.g.: different muting variants or functions
for complete press protection
• Modular expandability — the system simply grows along
with your requirements.
UE4457: Fast, direct in the field
• Automate directly in enclosure rating IP 67
• Can be used as stand-alone or also in a network
• Constant and super-fast shut-off with Fast-Shut-off
function
• Certified function blocks directly on-board
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S I C K | P R O D U C T S & A P P L I C AT I O N S — S A F E C O N T R O L S O L U T I O N S
23
Uniform configuration and diagnostics
EFI gateways
Product description
Customer benefits
• The integration of SICK safety sensors and systems in
higher-lever fieldbuses and networks is realised using
EFI gateways
• Complete system diagnostics
• Integration of the safety solutions in standard and
safety PLCs or in an existing network
• EFI gateways are available for following networks/fieldbuses: PROFIBUS-DP, PROFIsafe on PROFIBUS,
CANopen and Ethernet TCP/IP
• Uniform configuration and diagnostics in the entire
application
• Sensors connected can be displayed on the HMI via
the OPC server
• Remote diagnostics possible using the Ethernet
TCP/IP gateway
Diagnostics made easy
24
P R O D U C T S & A P P L I C AT I O N S — S A F E C O N T R O L S O L U T I O N S | S I C K
8010737/2008-11-19
Overview
Products
Services & Support
Applications in detail
Product selection
Integration
The SICK sensor system is integrated via the EFI on the
EFI gateway. Each EFI gateway has 2 EFIs to which, for
instance, S3000 safety laser scanners or C4000 safety
light curtains can be connected. Due to the integration on
the EFI, expanded sensor functionality, e.g., simultaneous
protective field evaluation (S3000 safety laser scanner) or
operating mode switching is available.
In addition, due to the usage of the EFI gateway, all
configuration and diagnostics data are available to the
customer for transfer to a higher level controller. The
PROFIsafe gateway has the special feature that safe data
can be exchanged bi-directionally between the SICK sensor system and the higher level controller.
Configuration
The gateway is configured using the CDS configuration
software supplied. The data to be exchanged between the
SICK system and the higher level controller are configured
using this software.
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S I C K | P R O D U C T S & A P P L I C AT I O N S — S A F E C O N T R O L S O L U T I O N S
25
It is hard to believe what can be
achieved with SICK
From planning through operation to modernisation:
International Service Solutions
With the installation of first-class SICK sensor technology,
the subject of safety is still a long way from complete.
Safety with “Sensor Intelligence” after all is a continuous
process which remains relevant throughout the whole life
cycle of a machine or plant: From planning through operation to modernisation.
With SICK “International Service Solutions” you profit in
all phases from the international know-how of the market
leader of safety products and the experience gained from
different sectors and countless applications.
S I C K I N T E R N AT I O N A L S E RV I C E S O LU T I O N S
COMPLIANCE & DESIGN
–
–
–
–
–
–
–
–
S I C K I N T E R N AT I O N A L S E R V I C E S O LU T I O N S
UPGRADE SERVICES
– PLS/S3000 upgrade kit
– LCUR1--411 upgrade kit
S I C K I N T E R N AT I O N A L S E R V I C E S O LU T I O N S
MODIFIC AT I O N
PRODUCT SUPPORT
–
–
–
–
–
–
On-site troubleshooting
Helpline support
Service tools
Spare parts
Exchange units
Workshop repairs
S I C K I N T E R N AT I O N A L S E R V I C E S O LU T I O N S
PLANNING
ENGINEERING
DESIGN
Safety
during all
phases of
the machine
life cycle
Risk assessment
Safety concept
Project management
Software design
Hardware design
Installation
Commissioning
Functional safety
assessment
– CE-conformance check
– CE certification
– Plant walk-through
S I C K I N T E R N AT I O N A L S E R V I C E S O LU T I O N S
COMMISSIONING
PRODUCT SUPPORT
– Commissioning check
– Helpline support
S I C K I N T E R N AT I O N A L S E R V I C E S O LU T I O N S
V E R I F I C AT I O N &
MEASUREMENTS
V E R I F I C AT I O N &
MEASUREMENTS
–
–
–
–
–
–
Accident investigation
Electrical equipment check
Periodic inspection
Machine safety inspection
Stoptime measurement
Noise measurement
O P E R AT I O N
–
–
–
–
–
Electrical equipment check
Initial inspection
Machine safety inspection
Stoptime measurement
Noise measurement
S I C K I N T E R N AT I O N A L S E R V I C E S O LU T I O N S
T R A I N I N G & E D U C AT I O N
– User training
– Seminars
– WebTraining
26
P R O D U C T S & A P P L I C AT I O N S — S A F E C O N T R O L S O L U T I O N S | S I C K
8010737/2008-11-19
Overview
Products
Services & Support
Applications in detail
Product selection
“
Compliance & Design
Safety from the start!
Over-sizing is prevented
and as a result competitiveness ensured!
“
“
“
“
Product support
”
Construction completed.
Everything perfectly installed. Now we can get started.
Trouble-free from the start.
”
”
”
Training & Education
Everything was explained in detail.
It is hard to believe what
can be achieved with SICK.
Verification & Measurements
Things change over time.
So it is better to check again
whether everything is still correct.
Upgrade services
At some point the technology became obsolete.
We found a solution together.
In no time everything was up to date again.
8010737/2008-11-19
”
S I C K | P R O D U C T S & A P P L I C AT I O N S — S A F E C O N T R O L S O L U T I O N S
27
Safety sensors simply integrated
Straightforward automatic hazardous area protection
on a palletizer station
SICK is continuously publishing examples of application
solutions on the Internet
www.sick.com
Task
A palletizer station is to be protected
using an emergency stop pushbutton that stops the pallet movement
immediately when it is actuated. The
movement is only allowed to be restarted after the Reset button has
been pressed and released again.
Implementation
This safety function can be realised
easily and reliably by connecting the
emergency stop pushbutton to an
UE43-4MR safety relay. This relay can
monitor the connections on emergency stop pushbuttons and safety
switches, and provides cross-circuit
detection in case of dual-channel
operation. It has 4 self-monitored
safety capable outputs. It provides an
EDM function (External Device Monitoring) for the devices that it switches.
If, as in the case described, a manual
reset is required, the reset function is
monitored to prevent the unexpected
starting of the machine due to an
electrical or mechanical malfunction
in the reset device. By linking the
emergency stop pushbutton to the
UE43-4MR safety relay, the palletizer
station is shut down quickly and
reliably on the actuation of the emergency stop pushbutton. A control unit
is not necessary.
28
Application overview
Task
Hazardous area protection
Industrial sector
Assembly, handling, robotics, automation
Application location/type of machine
Pallet store
Safety functions
Tool/machine protection, reset/restart
Product family
UE43-3AR/MR, ES21
Customer benefits
• Complete monitoring of an emergency stop pushbutton
• Small size: 4 safety capable outputs in 22.5 mm housing
• Fast response time: 10 ms
• With EDM (External Device Monitoring) and monitored reset function
P R O D U C T S & A P P L I C AT I O N S — S A F E C O N T R O L S O L U T I O N S | S I C K
8010737/2008-11-19
Overview
Products
Services & Support
Applications in detail
Product selection
Integration of a safety light curtain in the
emergency stop circuit on a press
SICK is continuously publishing examples of application
solutions on the Internet
www.sick.com
Task
A press is to be protected using a
safety light curtain. If the operator reaches into the press during
operation, the machine immediately
stops the dangerous movement. The
machine is only allowed to be able to
start again after the Reset button has
been manually actuated.
Application overview
Task
Hazardous point protection
Industrial sector
Machine tools and production systems
Application location/type of machine
Presses
Safety functions
Reset/restart, tool/machine protection
Product family
C4000 Eco, UE43-3AR/MR
Implementation
This task can be solved by connecting
a light curtain to a safety relay. The
safety relay monitors the safety capable outputs on the optical monitoring
device and stops the machine on the
interruption of the safety light curtain.
The UE48-3MR has 3 N/O contacts
and an additional N/C contact as a
status output.
It monitors the reset function. As it
only permits restarting after the Reset
button has been released, it ensures
the machine does not start unintentionally. An EDM function (External
Device Monitoring) is available for the
devices that are switched by the relay.
By directly linking the safety light
curtain to the UE48-3MR safety relay,
incorrect reaching into the machine
will result in the rapid shut down
of the dangerous movement on
the press. A safety controller is not
required.
8010737/2008-11-19
Customer benefits
• Any type of safety light curtain can be connected
• Small size: 3 safety capable outputs and one status output in 22.5 mm
housing
• Fast response time: 10 ms
• With EDM (External Device Monitoring) and monitored reset function
S I C K | P R O D U C T S & A P P L I C AT I O N S — S A F E C O N T R O L S O L U T I O N S
29
Safety automation without software
Safety automation on a wrap-around tray
packaging machine
SICK is continuously publishing examples of application
solutions on the Internet
www.sick.com
Task
A wrap-around tray packaging
machine picks up drink cartons and
places them on a tray insert. The
machine aligns the tray insert and
bonds it to a carrier (tray) that now
securely restrains the items during
transport.
The packaged items enter the system
via a tunnel that can be opened.
When closed, the tunnel prevents
direct reaching into the danger zone.
The conveyor belt must be stopped
when the tunnel is opened. The
outlet on the packaging machine is
to be protected against reaching in
using an electrosensitive protective
device. Nine service doors are to be
economically protected against opening. Emergency stop pushbuttons are
used to stop the entire machine in
case of danger.
Application overview
Task
Safety automation, hazardous point protection,
access protection
Industrial sector
Food & beverage
Application location/type of machine
Packaging machines
Safety functions
Emergency stop function, differentiation
between man and material (muting), safetyrelated stop function, reset/restart
Product family
C2000, Flexi Classic, L4000, RE300
Implementation
The tunnel is protected with an
RE300 non-contact safety switch.
When the tunnel cover is opened,
this switch shuts down the conveyor
belt and the machine: the dangerous
movements are stopped.
A C2000 safety light curtain is fitted
to the exit on the machine. This light
curtain is muted by a signal from the
PLC (programmable logic controller) and a WL27 photoelectric reflex
switch when the packaged items
leave the machine on their carrier. If
a person reaches in here, the C2000
shuts down the conveyor.
The nine doors on the machine are
secured using one L4000 photoelec-
30
tric safety switch and two deflector
mirrors. If one of these doors is
opened, the light beam is interrupted:
the L4000 sends a stopping signal
to the Flexi Classic. This controller
generates a shutdown signal that is
sent to the controller for the machine.
With the doors closed, the packaging
machine is re-started using a reset
button. The actuation of an emergency stop pushbutton interrupts the
supply of power to the machine.
All safety sensors are connected to
a Flexi Classic modular safety controller. The Flexi Classic performs
P R O D U C T S & A P P L I C AT I O N S — S A F E C O N T R O L S O L U T I O N S | S I C K
all the safety control functions. The
necessary logic can be selected using
rotary switches. Software is not necessary.
8010737/2008-11-19
Overview
Products
Services & Support
Applications in detail
Product selection
Customer benefits
• Flexi Classic replaces a series of safety relays, including a muting module
• The L4000 photoelectric safety switch replaces nine safety switches with one light beam
• Reduced hardware costs and wiring effort
• Shortened response time in comparison to relay
View of the logic functions in the
Flexi Classic configurator: logic at
a glance
Circuit diagram from the Flexi Classic configurator view: sensor connection and program selection at
a glance
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31
Simplest solution for demanding
customer requirements
Hazardous area and access protection
on a robot cell
SICK is continuously publishing examples of application
solutions on the Internet
www.sick.com
Task
In two neighbouring automatic cells,
two robots independently place workpieces on pallets. The working areas
of the robots are bounded by fences.
Access through two service doors is
to be protected by safety switches.
The safety switches act on the related
robot. Two emergency stop pushbuttons at the doors are also to stop the
robots. The vehicular access for the
fork lift truck is to be protected using
laser scanners that interrupt the
movement of the robots if one of protective fields they monitor is entered.
An emergency stop pushbutton on
each door as well as on the entrance
to the vehicular access stops both
robots. The monitoring devices are to
be linked by a control unit that is to
ensure both robots operate safely.
Application overview
Task
Safety automation, hazardous area protection
Industrial sector
Assembly, handling, robotics, automation
Application location/type of machine
Robot station
Safety functions
Safe gate function, emergency stop function,
reset/restart, tool/machine protection
Product family
Flexi Soft, ES21, S3000, i17S
Implementation
The Flexi Soft safety controller meets
these requirements intelligently and
easily. It secures the two robot working areas independent of each other.
The safety laser scanner can also
monitor a simultaneous protective
field. Using its EFI function (Enhanced
Function Interface), the Flexi Soft
can evaluate the two protective fields
independent of each other.
As a result the Flexi Soft only monitors the access to a robot if the robot
is in operation.
The logical configuration of the Flexi
Soft modular safety controller using
intuitive software with a graphical
32
user interface makes it possible to
design the application with complete
flexibility.
The contacts on the emergency stop
pushbuttons and safety switches,
dual-channel in each case, are
monitored for cross-circuits. It is
possible to monitor (external device
monitoring) the safety relays connected to the outputs.
The flexibility and easy usage of the
system makes it possible to realise
P R O D U C T S & A P P L I C AT I O N S — S A F E C O N T R O L S O L U T I O N S | S I C K
the application quickly and easily. The
circuit configuration can also be modified and expanded at any time. This
action can be undertaken straightforwardly in the safety controller with
the aid of an intuitive function blockbased logic editor. Additional devices
such as a safety command device for
safely setting up the system can be
connected using expansion modules.
The Flexi Soft system can be expanded to up to 144 inputs/outputs.
8010737/2008-11-19
Overview
Products
Services & Support
Applications in detail
Product selection
Customer benefits
• Direct sensor connection
• Fast response times
• Space saving
• Logic configuration as required via software
• Usage of the expanded sensor functions by means of the EFI
• Optional diagnosis module
• Modular construction: The controller grows with the application
• Easy field bus connection via diagnosis modules
Flexi Soft Designer logic configuration: a simple and efficient tool for
the configuration
Flexi Soft sensor configuration:
sensor configuration via drag and
drop
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33
Efficient solutions even for larger tasks
Hazardous point protection for material feed on a rotary
table
SICK is continuously publishing examples of application
solutions on the Internet
www.sick.com
Application description
Parts for tools are placed manually
in the recesses on a rotary table.
After the rotation of the table, a
robot processes the parts and then
places them on a conveyor belt for
further production steps. This process is repeated continuously. For
the protection of the tool, it must be
ensured that the rotary table is in
the correct position.
Application overview
Task
Hazardous point protection
Industrial sector
Machine tools and production systems
Application location/type of machine
Rotary table
Safety functions
Integration of safe automation in control system on same network, emergency stop function, safe position monitoring, safety-related
stop function, control modes and operating
mode selection, machine control (e.g. PSDI)
Product family
UE4457, C4000, IN4000
Implementation
The logic for the application is
defined directly on site at the rotary
table by the linking of inputs and
outputs on certified function blocks
in the UE4457 remote controller.
The UE4457 remote controller can
either be operated as an isolated
controller or in a network. As an
electro-sensitive protective device
for the protection of people, the
C4000 safety light curtain stops
the movement of the rotary table
if a person reaches into the protective field. The protective field
height prevents reaching into the
hazardous area. A second horizontal light curtain, cascaded with the
vertical C4000, protects against
standing behind the protective
device.
The “PSDI mode” function in
the controller initiates the rotary
movement of the table and in this
way ensures rapid and efficient
work at the insertion station.
This feature increases productivity
and provides the operator with
optimal protection at the workplace.
34
Safety position switches or a wearfree IN4000 non-contact safety
switch detect the position of the
rotary table. The non-contact safety
switch is evaluated directly in the
remote controller without any further
evaluation unit. A control device with
emergency stop pushbutton, reset
button and start button with LED
indicators rounds off the safety con-
P R O D U C T S & A P P L I C AT I O N S — S A F E C O N T R O L S O L U T I O N S | S I C K
cept. The components are connected
directly at the insertion station to a
UE4457 safety remote controller and
evaluated.
8010737/2008-11-19
Overview
Products
Services & Support
Applications in detail
Product selection
Customer benefits
• Optimally matched system components permit the best possible solutions
• Minimisation of the safety distances due to fast system response times and Fast-Shut-off functionality
• Cost saving due to reduced wiring effort and shorter commissioning
• UE4457 permits both stand-alone safety solutions and also subsequent integration into network solutions
The safety functions are realised
simply and conveniently with the
aid of certified function blocks.
The graphical programming provides not only clear information,
but at the same time also automatic, complete documentation.
In the online monitoring mode the
current state of the inputs and outputs as well as the results of the
logic can be displayed in colour at
any time.
The UE4457 remote controllers acquire the signals from the
switches and the optical sensors
in the system directly in the field
without long cable runs.
The UE4470 flexible safety controller flexibly processes the signals
and controls the various cut-off
paths.
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35
sens:Control — Selection Guide
36
P R O D U C T S & A P P L I C AT I O N S — S A F E C O N T R O L S O L U T I O N S | S I C K
8010737/2008-11-19
Overview
Products
Services & Support
Applications in detail
Product selection
8010737/2008-11-19
S I C K | P R O D U C T S & A P P L I C AT I O N S — S A F E C O N T R O L S O L U T I O N S
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8010737/2008-11-19 ∙ IL/FD ∙ Printed in Germany (2008-11)
Subject to change without notice ∙ 00 WB USmod int32
OUR COMPETENCE IN THE BUSINESS SEGMENTS
F A C T O R Y A U T O M AT I O N
L O G I S T I C S A U T O M AT I O N
P R O C E S S A U T O M AT I O N
With its intelligent sensors, safety systems, and auto ident applications, SICK
realises comprehensive solutions for
factory automation.
Sensors made by SICK form the basis
for automating material flows and the
optimisation of sorting and warehousing
processes.
Analyzers and Process Instrumentation
by SICK MAIHAK provides for the best
possible acquisition of environmental
and process data.
• Non-contact detecting, counting,
classifying, and positioning of any
types of object
• Accident protection and personal
safety using sensors, as well as
safety software and services
• Automated identification with bar
code and RFID reading devices for
the purpose of sorting and target
control in industrial material flow
• Detecting volume, position, and contours of objects and surroundings
with laser measurement systems
• Complete systems solutions for gas
analysis, dust measurement, flow
rate measurement, water analysis or,
respectively, liquid analysis, and level
measurement as well as other tasks
Worldwide presence with
subsidiaries in the following
countries:
Nederlands
Please find detailed addresses and
additional representatives and agencies
in all major industrial nations at
www.sick.com
Australia
Belgium/Luxembourg
Brasil
Ceská Republika
China
Danmark
Deutschland
España
France
Great Britain
India
Israel
Norge
Österreich
Polska
Republic of Korea
Republika Slovenija
România
Russia
Schweiz
Singapore
Suomi
Sverige
Taiwan
Türkiye
USA/Canada/México
Italia
Japan
SICK AG | Waldkirch | Germany | www.sick.com
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