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TT14
Omron magazine — Technology&Trends 14
The optimal path to safe machines
Helios Energy Europe
Beaphar and DeviceNet Safety
How the Omron Safety Service helps customers
by supervising the process and drawing up risk
assessments to the implementation of
documentation
Maximum Safety in the automated production of
renewable energy sources
Beaphar has been developing and producing
medicines and care products, as well as
premium food for pets, for more than 65 years
More on page 4
More on page 6
More on page 14
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3
Safety… at your service!
8
12
Many years ago, Omron’s founder, Kazuma Tateishi created the
company motto, “At work for a better life, a better world for all”. At
Omron, we are still very much inspired by this motto and believe that
Safety is fundamental to this vision, and when applied to Industrial
Automation, Machine Safety becomes a key focus.
Safety has become a much more prevalent issue for our society, and
this is shown in both the developments in safety technology and the
resulting business levels, which appear to have been largely
unaffected by the recent economic crisis. The trend is moving from
reducing the risk of injury or death to preventing them all together,
6
maximizing safety and reducing downtime.
With the development of software based safety systems and
integrated safety features within machine control, the safety system
became a driver of machine productivity. Key issues raised by the
machinery directive, like inherent safety design, or the transition from
EN954-1 Categories to the more realistically adjusted performance
4
levels defined in EN 13849-1, become common issues in modern
machine safety.
Omron – almost unique in the market – owns all of its safety related
core technologies, from leading know-how to design and production
of reliable forcibly guided relays and safety switches, to safety
sensors using superior photoelectric competence, up to embedded
safety functions in machine and motion controllers and drives.
Safety is at the core of our company, and is likely to be where Omron
fulfills your needs most. Learn more about our experience in safety,
and safety services, which will help you to design safe and efficient
machines!
Cover:
Let’s keep the balloon from
bursting!
Today, Safety in machinery
is continuously evolving.
The probability of an
“unsafe failure” must always
be taken into consideration
when implementing
necessary safety measures.
Division Manager
Sensing Safety and Component Division
EMEA Countries
pa g e 1 0
Safety Service
Competence Network
Safety in Motion since 2004
Interview with Mr Hochrein, Mr Goebbels
and Mr Kothes.
our competence in safety risk assessment, our wide product portfolio
Maurizio Poli – Editor in Chief
pa g e 4
pa g e 6
Maximum Safety in the automated
production of renewable
energy sources
Talking about Helios Energy Europe
(Heliene).
pa g e 8
Yes you CAN!
User defined CAN Communication.
10
G5 servo drive and MX2 inverter.
pa g e 1 2
TechnoGR Safety Services
Protect your business.
pa g e 1 4
Beaphar and DeviceNet Safety
Developing and producing medicines,
care products and premium food for pets
for 65 years.
pa g e 1 5
Colophon & Contact
14
5
4
Talk about...
Safety Service
Competence Network
The optimal path to safe machines
Peter Goebbels
The CE marking of machinery and plants requires extensive knowledge of the
relevant directives and standards. This applies to machine and plant builders
but also to operating companies. How the Omron Safety Service helps customers
by supervising the process, drawing up risk assessments to the implementation
of documentation is described by Peter Goebbels (Product Manager for Safety,
Omron), Lars Kothes (CEO, Kothes! Technische Dokumentation) and Ulrich
Hochrein (EDAG) in an interview with Regina Berg-Jauernig, Editor of
GIT SICHERHEIT + MANAGEMENT magazine.
Regina Berg-Jauernig: Mr Hochrein, could you please provide us with a brief
insight into the requirements of the Machinery Directive for which the network
intends to support fulfilment with the safety service?
Lars Kothes
Ulrich Hochrein: Firstly, we must not reduce the requirements to the Machinery
Directive only. The requirements of the European domestic market directives are
far-reaching and the distributor (not necessarily always the manufacturer) must
confirm that the requirements of all directives concerned have been fulfilled in
their entirety for his product. Machines must pass the right conformity
procedure, be correctly marked, be adequately documented and, of course, be
safely constructed, installed and put into operation. With ingenuity and
knowledge of current state-of the-art technologies, the safety service
competence network determines which systems and products are right for the
task. Many different experts bring their concentrated specialist knowledge to all
issues mentioned to the network. An individual can hardly fulfil these
comprehensive requirements, especially in the case of specific, unusual tasks.
Regina Berg-Jauernig: Unlike other companies in the
industry, you have chosen a partner model for the
organisation of these services. How does this model work
in particular – and who takes on what role here?
Peter Goebbels: Here, we are falling back on partners who
have already successfully worked with Omron as system
integrators for many years and have often proven their
competence in engineering and services. Safety technology
specialists complement the network as service partners
where sound, expert knowledge is required.
Regina Berg-Jauernig: Mr Kothes, your company takes on
the subject of technical documentation. How do you
support the customers in this?
Regina Berg-Jauernig: Mr Goebbels, the service has
already been introduced in Italy and thanks to the
acquisition of STI you have a network in the USA.
According to your planning, how will the service be
organised on a European and International level?
Peter Goebbels: Omron is gradually building up an
extensive network which can operate internationally. Other
industrial nations will soon be included. Consequently, we
will be able to meet the demands of customers who operate
between countries or even have global structures.
The Omron sales team will prepare intensively to get off to a
good start in 2011. The SPS/IPC/Drives trade show in
Nuremberg offers the ideal framework with which to present
this new service from Omron to the professional public.
Lars Kothes: With our employees, we cover the entire area
of technical documentation: from risk assessment through
instruction manuals to after-sales information. Our criteria
is the valid minimum of requirements from standards and
directives. Through consultation, analysis and use of up-todate software, we manage to compile high value, and
above all for the end customer, useful documentation at a
reasonable cost.
Ulrich Hochrein
Read more about the safety service from Omron on page 12
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Maximum Safety in the
automated production of
renewable energy sources
Precision and safety are the key words for Helios Energy Europe (Heliene), one of Spain’s leading manufacturers
of high-output solar panels, used for commercial-scale electricity generation.
Heliene applies maximum safety in its
solar panel manufacturing lines,
which are highly automated and
include robots.
Spain enjoys more hours of sunshine
temperatures of 150°C. The laminated
than almost any other European
panels must have all air removed from
country, so it is hardly surprising that
between the layers, as this would
it is one of the leaders in the
adversely affect the energy generating
development, manufacture and
performance. The final stage is to
installation of photovoltaic energy
assemble the panels into aluminium
systems. These generate electricity
frames before they are tested in a
from sunlight, using solar panels of
solar simulation to make sure that
photovoltaic cells, and they are
they meet the required standards.
increasingly used as
a source of
The whole process is
renewable energy,
“The need for precision carried out using a
especially for newly
line of robots, with
is paramount.”
built houses, offices
very little human
and factories.
intervention apart
from machine
Helios Energy Europe (Heliene) is one
control, visual inspection and some
of Spain’s leading manufacturers of
cleaning of the products as they move
high-power (200W to 250W)
down the line. The need for precision
photovoltaic modules, which are used
is paramount, because once the
mainly by industrial companies and
panels are laminated, it is almost
for generating electricity on a
impossible to rectify any defects. In
commercial scale. The company has a
addition, safety is a key consideration,
reputation for making high quality and
and the delicate – and expensive –
innovative products that are both
materials must be handled with
efficient and competitively priced. To a
extreme care to avoid damage, or
large extent, Heliene’s reputation
injury to the trained staff who work
derives from its customised
the line.
production lines which are highly
Advanced safety systems
automated, to optimise productivity.
Workers can visualize and accede to
Precise positioning
the operation of each of the robots, as
The solar panels are made up of
well as all the parameters controlled
156mm square cells, which are
in the production line through the
precisely positioned and linked in 6 x
NS10 series, interfacing with Omron
10 arrays with short ribbons of copper.
motors and inverters, sensors, relays
These are precisely positioned on to a
and controllers. This ensures the
glass panel and soldered together,
precision which is needed for quality
before the panel is laminated at
manufacturing.
The safety system is controlled by an
NE1A Safety Network Controller, which
has expansion modules along the
production line on a DeviceNet bus.
This set-up controls the emergency stop
pushbuttons at each of the robot
stations, limit switches on the safety
doors around the robots, and F3S-TGR-CL
safety light curtains protecting the
loading/unloading sections.
José Cardenas, part of the management
team at Heliene, explains that using
automatic systems for both control and
safety has improved both reliability and
precision in the production process:
“Compared with previous lines, we get
more speed as well as improved
quality, and relying on a single brand
for the equipment makes maintenance
and expansion much easier.”
Reliable, versatile and flexible
Oscar Chillón, Process Engineer,
agrees with this: “Robotic
manufacturing processes like this
need production and safety systems
that are reliable, versatile and flexible.
We’ve achieved that with this line, and
we’ve made productivity improvements
as a result.”
Spain has committed itself to reducing
its reliance on non-renewable energy
sources. It is estimated that by 2020,
solar power could be generating as
much as 20 GW of the country’s
electricity, compared with 1 GW at the
beginning of 2008, and Heliene is
well-placed to support this ambition.
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Over the past 20 years, Controlled Area Network (CAN) technology has become the basis for
communication between electronically controlled devices in a wide range of equipment.
Originally developed as a serial bus for vehicle electronics, it is now used in applications as
diverse as trains, X-Ray scanners, escalators and coffee machines.
Yes you CAN!
Widely used CAN hardware based
protocols include CANopen,
DeviceNet, J1939 and NMEA 2000.
Besides these open standards, some
proprietary CAN protocols are only
used by a specific equipment
manufacturer. This is hardly
surprising, because no car
manufacturer, for example, wants
anyone else to change the way their
braking or fuel delivery systems work.
may call for a complete system
redesign.
PLCs are theoretically ideal for such
situations, because they have many
communication interfaces, and are
easily re-configured and
re-programmed. What’s needed is a
user-defined CAN unit that can be
installed in the PLC to send and
receive frames over the CAN bus: in
order to meet just
User-defined CAN
this need the
systems
Omron’s CORT21
“Ideal for applications module has been
One of the
such as packaging
advantages of CAN is
developed. The
that it is robust and
CORT21 is truly
machines, robots,
easy to use, making it
protocolships.”
ideal for applications
independent, and is
such as packaging
available for both
machines, robots,
the modular
ships, and mechanical handling
CJ-series PLC, and the rack-based
equipment. Traditionally,
CS-series.
manufacturers designed their own
control systems for these CAN
The unit can be set to any baudrate up
installations, which can cause
to 1 Mbps, so even if the proprietary
problems when there is a need to
network has a non-standard rate, it
upgrade: replacing obsolete parts or
can still communicate. As the unit has
implementing the latest technologies
no fixed protocol, standard PLC
commands are used to set up all
parameters on the CORT21, such as
memory buffers and message
structures. Any memory area can be
allocated for the send and receive
buffers, the send triggers and the
receive flags. In total, up to 640 send
and 640 receive buffers can be
assigned.
Working independently
Once configured, the CORT21
communicates independently of the
PLC CPU. It monitors the trigger area
and reads the send buffers to fill the
CAN frames it sends out and extracts
data from passing CAN frames that
match its filter settings. The CORT21
also has extensive diagnostics that
show the status of the unit and of the
CAN-network, as well as the number of
pending CAN-messages in the receive
and send queues.
The CORT21 enables machine makers
to rethink the control solution on
existing equipment. A PLC can be
programmed and re-programmed,
even remotely, so that replacing a
bespoke control board with a PLC
allows control functions to be easily
modified as required. This gives
machine makers new opportunities to
contact existing customers to offer
upgrade packages on in-service
equipment. In addition to the sales
advantage, there are significant longterm customer-relationship benefits in
providing improved performance
without the need for major financial
investment.
Seamless integration
It’s in new installations that the
CORT21 really comes into its own. For
instance, diesel engines on a CAN
J1939 system controlled by a PLC can
be used on ships, trucks, buses,
excavators or forklift trucks. All that’s
needed is simple programming: and
the same technology can be used to
control everything from power-takeoffs to fuel monitoring.
You can now order the new CAN brochure on:
www.industrial.omron.eu
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Safety in Motion since 2004
In 2004, Omron launched the first built-in safety inverter drive – the L7. It was simply a case of putting together what
belonged together. Since then Omron has continued the trend of offering customers safety products compliant with
the latest safety legislation with improved functionality, such as the F7 and V1000 inverters and the Sigma-II servo
drive. Now, Omron introduce to the market the new MX2 drive and the Accurax G5 servo drive, both complying with
the latest safety regulations in order to enable our customers to make modern machines safer and more efficient.
Accurax G5
MX2 inverter
Reduce hardware and wiring
complexity
The Standard Safety Circuit (1)
requires one contactor at the output of
the Inverter to break the power to the
motor. Additionally, each contactor
confirms its status with a digital
output to the safety controller.
Accurax G5 – Integrated safety as standard.
The G5 servo drives comply with:
The built-in safety of the Accurax G5 servo drive provides multi-drive
connection with a single safety relay circuit. The redundant safety inputs and
the external device monitoring (EDM) output can be linked from one servo
drive to another without using additional safety relays for interfacing. Up to 8
servo drives can be connected to a single safety controller, saving hardware
and wiring costs.
• Performance Level d (PL d) according
to ISO 13849-1
• Safety function STO (Safe Torque
Off) according to IEC 61800-5-2
• Safety Integrity Level 2 (SIL 2)
according to EN 61508
• Safety Category 3 (Cat. 3) according
to EN 954-1
G5 drives provide integrated safety across its entire power range from 100W
to 15kW (100, 200 and 400V) and the safety function is available when using
any of the different control methods such as EtherCAT, Mechatrolink-II,
Analogue and Pulse train control.
With the built-in safety function (2),
only a direct connection to the safety
controller is needed.
MX2 inverter – Integrated safety as standard.
MX2 inverter complies with:
Each MX2 inverter provides a redundant safety input and one external device
monitoring (EDM) output. The EDM output confirms the safety status of the
inverter, saving you the cost and wiring of external devices to carry out the
same function.
• Performance Level d (PL d) according
to ISO 13849-1
• Safety function STO (Safe Torque
Off) according to IEC 61800-5-2
• Safety Integrity Level 2 (SIL 2)
according to EN 61508 and EN
62061
Easy integration into the machine safety circuit
MX2 inverters can be easily integrated into the safety circuit. The safety
inputs can be linked from one inverter to another without additional safety
relays.
You can now order the new MX2 brochure on:
www.industrial.omron.eu
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TechnoGR Safety Services
In the 21st century, machine manufacturers and end users alike must guarantee the safety and security of anyone and everyone who will come into contact with their machines. European and national worksite safety regulations are continually changing and evolving but still it is essential that your machines comply with all applicable legislation.
Protect your business
Member of Omron Europe
Accidents in the workplace can cause
major problems for your business,
ranging from possible legal action
through lost production to impacts on
staff morale, corporate reputation and
profitability. The TechnoGR Safety
Service supports safety throughout
the entire lifecycle of your machines
and helps you to protect your
business.
Partner network throughout
Europe
The TechnoGR Safety Service network
is an integrated part of the Omron
Europe organization and available in
most European countries. This
supports your operation if your
customer is operating your machine in
another country. You and your
customer will benefit in using the
documentation that was prepared by
the TechnoGR Safety Service partners
during the design and installation of
the machine. This reduces effort in
initial inspection as well as in
periodical 6- or 12-month inspections.
Support throughout the entire
machine lifecycle
Safety is part of every phase of the
entire machine life cycle, from the
design phase, to the operational
phase, and finally ending when the
machine is put out of service.
In the design phase, our specialized
partner network can support you in
risk assessment, help you set up the
proper documentation for your
specific machine and finally assist in
the CE-marking process of your
machine according to the relevant
European or Global directives. This
covers the Machinery Directive as well
as the EMC- or Low-Voltage Directive.
TechnoGR Safety Service customers
benefit from the information in the
TechnoGR Safety News. These
newsletters will keep you up to date
when directives or standards change.
All selected TechnoGR Safety Service
partners and safety experts are well
trained and have many years of
experience in all kinds of safety. The
European partner network ensures
support with the right knowledge and
experience, depending on your real
needs. This offer covers
documentation according to the
Machinery Directive, risk assessment,
electrical tests, stopping performance
tests and many more. TechnoGR safety
experts help you to select and get the
proper components for the
safeguarding of your machine,
irrespective of whether it is
mechanical or electrical when
installing and setting up the machine.
European and local directives,
standards and rules are the basis for
the training that the TechnoGR Safety
Service provides along with the initial
inspection before the machine is put
into operation or the periodical
inspection of the safety system on a
6- or 12-month basis when the
machine is fully operational. The
TechnoGR Safety Service offers you
years of experience working closely
with the world’s top machine
manufacturers and the associations
who define international safety
regulations.
During the installation of the machine
in its final workplace, training and
information of the staff operating the
machine is a key element to operate
the machine safely.
For further information please contact your local Omron Sales representative or
visit our website www.industrial.omron.eu
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Beaphar and DeviceNet Safety
Beaphar has been developing and producing medicines and care products, as well as premium food for pets,
for more than 65 years.
About Beaphar
Engineering
New extrusion line
At Beaphar, QUALITY is the key focus.
As a veterinary pharmaceutical
company, Beaphar is obliged to
comply with European Directive
91/412/EEC. This directive is well
known and denotes “GMP” (Good
Manufacturing Practice). Compliance
with the list of requirements is not
optional, but obligatory. Compliance
ensures that the manufacturing permit
for the production of veterinary
medicines is retained and
safeguarded. Every day everyone
within the organisation is involved in
complying with this directive in some
way. The management of all processes
that take place has to be
demonstrable and verifiable.
Beaphar has an on-site engineering
department that is supported by a
technical service. The engineering
department is responsible for the
design and modification of both
existing and new production lines. The
subject of machine safety is playing
an ever greater role in the design and
modification of production lines.
Beaphar has set itself the goal of
ensuring that machine safety devices
comply with the new EN ISO 13849-1
standard. To this end, the engineering
department performs its own risk
inventories, and with the
manufacturer’s support, the correct
components and systems are chosen
in order to ensure correct safety.
Last year, Beaphar developed a new
extrusion line with which different
types of premium animal feed can be
produced. Incorporated in this line are
extruders, a hammer mill, a cutting
and rolling installation and various
filters and driers. Inspection hatches
or protective devices are fitted in most
parts of this extrusion line. If these
are opened, this can be a risk for the
user, because they can come into
contact with the product or with
dangerous parts of the machine. To
prevent this risk, every hatch or
protective device is fitted with one or
more door switches.
The extrusion line has a considerable
reason for Beaphar opting for this
number of door switches, emergency
system is that in the control room it is
switches and other
possible to see
safety devices. On
immediately where
account of the high
unsafe situations
number of
occur. Previously, it
components,
“It is possible to see was necessary to
Beaphar has opted
search for the open
immediately where
for a DeviceNet
hatch, or to find out
unsafe situations are which emergency
Safety controller plus
occurring.”
a number of safety
switch had been
slaves from Omron
operated; this is now
Electronics. The
immediately evident
advantages to
on a computer
Beaphar are that,
screen. This results
because of the bus architecture, less
in a significant time saving, as the
wiring is necessary. As the system is
production line can be operational
software-based, modifications are
again much more quickly.
easy to make. However, the main
Safety network controller NE1A
Colophon & Contact
Omron Europe B.V.
Wegalaan 67-69, NL-2132 JD, Hoofddorp, The Netherlands.
Tel: +31 (0) 23 568 13 00, Fax: +31 (0) 23 568 13 88, www.industrial.omron.eu
is the customer magazine of Omron Europe B.V.
Austria
Tel: +43 (0) 2236 377 800
www.industrial.omron.at
Italy
Tel: +39 02 326 81
www.industrial.omron.it
Spain
Tel: +34 913 777 900
www.industrial.omron.es
Belgium
Tel: +32 (0) 2 466 24 80
www.industrial.omron.be
Middle East & Africa
Tel: +31 (0) 23 568 11 00
www.industrial.omron.eu
Sweden
Tel: +46 (0) 8 632 35 00
www.industrial.omron.se
Czech Republic
Tel: +420 234 602 602
www.industrial.omron.cz
Netherlands
Tel: +31 (0) 23 568 11 00
www.industrial.omron.nl
Switzerland
Tel: +41 (0) 41 748 13 13
www.industrial.omron.ch
Denmark
Tel: +45 43 44 00 11
www.industrial.omron.dk
Norway
Tel: +47 (0) 22 65 75 00
www.industrial.omron.no
Turkey
Tel: +90 212 467 30 00
www.industrial.omron.com.tr
Finland
Tel: +358 (0) 207 464 200
www.industrial.omron.fi
Poland
Tel: +48 (0) 22 645 78 60
www.industrial.omron.pl
United Kingdom
Tel: +44 (0) 870 752 08 61
www.industrial.omron.co.uk
France
Tel: +33 (0) 1 56 63 70 00
www.industrial.omron.fr
Portugal
Tel: +351 21 942 94 00
www.industrial.omron.pt
More Omron representatives
www.industrial.omron.eu
Germany
Tel: +49 (0) 2173 680 00
www.industrial.omron.de
Russia
Tel: +7 495 648 94 50
www.industrial.omron.ru
Hungary
Tel: +36 1 399 30 50
www.industrial.omron.hu
South Africa
Tel: +27 (0) 11 608 3041
www.industrial.omron.co.za
Publisher:
Editor in chief: Editorial office:
Copyright:
Omron Europe B.V.
Wegalaan 67-69
NL-2132 JD Hoofddorp
The Netherlands
Tel: +31 (0) 23 568 13 00
Fax: +31 (0) 23 568 13 88
www.industrial.omron.eu
Maurizio Poli
Karen Wassink, Johanna Lampe, Kristina Krüger
Omron Europe B.V., 2010
Specifications subject to change without notice.
Although we strive for perfection, Omron Europe BV and/or its subsidiary and
affiliated companies do not warrant or make any representations regarding the
correctness or completeness of the information described in this document.
We reserve the right to make any changes at any time without prior notice.
CD_EN01+TechnologyTrends14
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