Innovations in Safety: Bridging Safety onto
Innovations in Safety:
Bridging Safety onto
Automation Networks
Zachary Stank
Product Specialist
Phoenix Contact USA, Inc.
Bridging Safety onto Automation Networks
• The State of the US Safety Industry
• Creating Value by Networking Safety
• Looking to the Future of Safe Automation
Scalability
The State of US Safety: Industry Trends
Wired Relays
Functionality
The State of US Safety: Chaining Sensors
• A non-contact door sensor system, daisy-chained
into a single safety relay
The State of US Safety: Chaining Sensors
• Opening any of the doors will break the logic
connection and safety open the relay contacts
• The relay will give diagnostics feedback for an open
door, but no indication of which door it was
The State of US Safety: Chaining Sensors
• Closing the safety gate and pressing the reset will
re-enable the relay circuit
The State of US Safety: Chaining Sensors
• If one of the channels of logic fails (is welded or is
stuck), the error is indicated on the relay
The State of US Safety: Chaining Sensors
• Opening another gate in the series will open the
second contact, masking the fault
The State of US Safety: Chaining Sensors
• Opening another gate in the series will open the
second contact, masking the fault
The State of US Safety: Chaining Sensors
• With the fault masked, the relay can be restarted
while the fault still exists in the chain
The State of US Safety: Chaining Sensors
• EN ISO 14119 has been developed
tackling the issue of periodic movable
guards wired in series
• New multifunction safety relays are
available with several inputs for
independent sensor connection
• New sensor technology allows for
chaining of inputs while maintaining
diagnostic coverage
Scalability
The State of US Safety: Industry Trends
Wired Relays
Multifunction Relays
Configurable Relays
Functionality
Application Example: Robotic Weld Cell
• Three separate safety inputs:
• Emergency Stop
• Safety Gate
• Light Curtain
• Two different delay-off times
• Safety Gate outputs are isolated from
Light Curtain, but Emergency stop
shuts everything off.
Application Example: Robotic Weld Cell
Standard Relay Solution
Configurable Relay Solution
Configurable Safety Relays
• Easy definition of safety functions with simple software
• Software control removes complex relay logic wiring schemes
• Most configurable relays offer status communication through
common industrial automation protocols
Scalability
The State of US Safety: Industry Trends
Wired Relays
Multifunction Relays
Configurable Relays
Networkable Safety Systems
Functionality
Programmable Controllers
Bridging Safety onto Automation Networks
• The State of the US Safety Industry
• Creating Value by Networking Safety
• Looking to the Future of Safe Automation
Networked vs Hardwired Safety Control
Control Cabinet
Final Assembly
Welding Sub-station
Networked vs Hardwired Safety Control
Control Cabinet
Final Assembly
Welding Sub-station
Networkable Safety & Safety PLCs
• Distributed on an automation network, place IO where the
sensors are and connect safely through your PLC.
• Real-time diagnostics for data logging and simple feedback
integration on HMI screens.
• Using the horsepower of a PLC means more IO can be
connected and monitored.
Scalability
The State of US Safety: Industry Trends
Wired Relays
Multifunction Relays
Configurable Relays
Networkable Safety Systems
Functionality
Programmable Controllers
Bridging Safety onto Automation Networks
• The State of the US Safety Industry
• Creating Value by Networking Safety
• Looking to the Future of Safe Automation
Scalability
The Future of Safe Automation
Wired Relays
Multifunction Relays
Configurable Relays
Networkable Safety Systems
Functionality
Programmable Controllers
Integrated Safety and Smarter Sensors
• As PLCs continue to get smaller and
prices shrink, they may begin to
overtake typical Configurable Safety
Relay systems
• Distributed safety is more popular than
ever, and we are starting to see
sensors and end devices already
setup as Networkable Safety devices
Safety in an Artificially Intelligent Environment
• What are the safety requirements if no humans are present?
Review
• In the US, it is still very common to find chained sensors, and
new relay and sensor technology is coming to market to
increase the diagnostic capabilities of this practice
• IIoT is increasing demand for networkable safety systems,
which can provide comprehensive diagnostics and improve
system availability
Zachary Stank
Product Specialist
Phoenix Contact USA, Inc.
586 Fulling Mill Road
Harrisburg, PA 17112
United States of America
717-944-1300 x3832
[email protected]
@ZRStank
www.phoenixcon.com
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