Pack­ag­ing sys­tem mak­ers can en­joy safer net­work­ing of mod­u­lar ma­chines

DEMM Engineering & Manufacturing - - PRODUCT WATCH -

Sick has equipped its flexi soft mod­u­lar safety con­troller with new func­tion­al­i­ties. With the flexi loop func­tion­al­ity up­grade, pack­ag­ing sys­tem man­u­fac­tur­ers ben­e­fit from the safe net­work­ing of mod­u­lar ma­chines, and with the drive mon­i­tor mo­tion con­trol mod­ule from the safety ori­ented mon­i­tor­ing of drives.

With the cas­cad­ing of safety sen­sors, the safe net­work­ing of mod­u­lar ma­chines, and safety ori­ented drive mon­i­tor­ing, the firm pro­vides ef­fi­cient safety so­lu­tions for all phases of the pack­ag­ing process.

Ma­te­ri­als sup­ply, ser­vic­ing, and main­te­nance work, as well as er­ror rec­ti­fi­ca­tion, are the most im­por­tant rea­sons that pack­ag­ing ma­chines are of­ten pro­vided with a va­ri­ety of safety doors, ser­vice pan­els, or cov­ers.

Along with th­ese, emer­gency stop push-but­tons are almost al­ways pro­vided, as well as safety laser scan­ners or safety light cur­tains in some ap­pli­ca­tions where ma­chine open­ings with­out a me­chan­i­cal, phys­i­cal guard must be ac­cessed.

Due to the spe­cial screened ca­bles in­volved, as well as the dis­crete wiring and safe in­puts for the safety con­troller, in­te­grat­ing all of th­ese switches and sen­sors sep­a­rately would un­til now have in­curred sig­nif­i­cant costs. The flexi loop func­tion­al­ity up­grade ful­fils the re­quire­ment for cost-sav­ing cas­cad­ing of safe switches and sen­sors, with which safety doors and ser­vic­ing pan­els on ma­chines are pro­tected up to per­for­mance level (PL) E in ac­cor­dance with DIN EN ISO 13849-1.

Up to 32 sen­sors, even those pro­duced by other man­u­fac­tur­ers, can be cas­caded and re­ceive volt­age sup­ply via loop nodes in en­clo­sure rat­ing IP67. This min­i­mizes ex­pen­di­ture on ca­bling and frees up safety con­troller in­puts. Here the power sup­ply and com­mu­ni­ca­tion paths be­tween the in­di­vid­ual loop nodes can be as long as 30 m, mean­ing that a full “loop” may amount to a to­tal length of 960m. The con­nec­tion is achieved via an un­screened stan­dard cable with M12 con­nec­tors.

Flexi loop almost elim­i­nates the cur­rent costs for wiring and for safety in­puts and out­puts, and, un­like con­ven­tional se­ries con­nec­tion, de­tects if con­se­quen­tial er­rors are masked by the se­ries con­nec­tion.

Fur­ther­more, un­like dis­creet wiring, the re­sponse time of the whole sys­tem is re­duced, as the re­sponse time of flexi loop is sig­nif­i­cantly shorter than the sum of the re­sponse times of the in­di­vid­ual sen­sors. As the flexi loop strand mon­i­tors each sen­sor in­di­vid­u­ally, it pro­vides com­pre­hen­sive di­ag­nos­tic in­for­ma­tion dur­ing run­ning op­er­a­tion. The du­ra­tion and costs of ma­chine down time in a pack­ag­ing line are min­i­mized in an ef­fi­cient man­ner, and avail­abil­ity is op­ti­mized.

The ef­fi­cacy of safety ori­ented op­ti­miza­tion of in­di­vid­ual ma­chines is, how­ever, de­pen­dent on link­ing the con­trol sys­tems of the in­di­vid­ual sys­tem mod­ules and in­te­grat­ing their safety func­tions process log­i­cally through the bi-di­rec­tional com­mu­ni­ca­tion of the safety sig­nals.

The flexi line func­tion­al­ity up­grade en­ables up to 32 ma­chine el­e­ments of a com­plete pack­ag­ing line to be net­worked safely, with­out ad­di­tional mod­ules and over dis­tances of up to 1000m be­tween the sta­tions. In this way, es­tab­lished and sim­u­lated safety func­tions can be in­stalled eas­ily dur­ing fi­nal assem­bly, or com­mis­sion­ing at the end cus­tomer’s in­stal­la­tion – with­out ad­di­tional elec­tronic com­po­nents, or ex­tra ex­pen­di­ture on soft­ware or pro­gram­ming. It means the ad­di­tion of ma­chine mod­ules and their con­trol sys­tems, for safety pur­poses, can be achieved in the sim­plest and most ef­fi­cient way.

An ad­di­tional ben­e­fit is the mi­gra­tion ca­pa­bil­ity of safe drive mon­i­tor­ing with the drive mon­i­tor. Ex­pan­sion of up to six drive mon­i­tor mod­ules is pos­si­ble, which is ideal for achiev­ing in­tel­li­gent mul­ti­axle ap­pli­ca­tions with up to 12 drives.­eren­quiry #140908

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