Wireless Safety

Implementation of a robotic cell with the Safety Simplifier

System Control circuit

Safety Simplifier on the control cabinet of a processing machine: Thanks to the integrated safety PLC, all safety functions of the processing machine can be applied or the Safety Simplifier acts as an interface between the individual components.


Simplifier installed on a tool stand

The Safety Simplifier installed on the tool stand monitors the safe tool change of the robot.


Simplifier on a rolling gate

Operational unit and monitoring of the safety switch (e.g. tGard) on the sliding door.


robot cell

Safety Simplifier evaluates the OSSD signals of the muting light grid and provides the override function in case of faults.

Simplifier on a light grid

The Safety Simplifier installed on the control cabinet of the robot for safe communication and shutdown of the robot.

robot control

Operational unit and monitoring of the safety switch on the wing door.

Simplifier installed on a fence

Safe Wireless Communication with Safety PLC Safety Simplifier

 

Application description

The following drawing shows a processing machine automated with a handling robot. For the implementation of the safety technology, only three decentralized Safety Simplifier are necessary for the evaluation of all safety functions. Consequently, a safety PLC and the otherwise mandatory control cabinet are no longer necessary. Your planning effort simplifies, the plants can be standardized and expanded in a modular manner. Additional robots or doors that are required, will be quickly connected thanks to further Safety Simplifier. Using the clear system and software design, the validation of hardware and software will be quickly and comfortably implemented.



Drawing of a robot cell with the Simplifier in action

Requirements of the Maschine

A standard processing machine with safety technology (door 1 and door 2 + internal emergency stop, speed monitoring etc.) that is already internally connected (e.g. safety PLC) usually requires for external connection following interfaces:

Easy planning

Thanks to the IP65 protection class of the Safety Simplifier, an external safety PLC or even a control cabinet for the safety technology are no longer necessary for your robot cell. The wiring effort of the safety components is reduced to a minimum using the safe wireless communication.


Reduction of commissioning time

Thanks to the IP65 protection class of the Safety Simplifier, an external safety PLC or even a control cabinet for the safety technology are no longer necessary for your robot cell. The wiring effort of the safety components is reduced to a minimum using the safe wireless communication.



wireless communication

Requirements of the machine

A standard processing machine with safety technology (door 1 and door 2 + internal emergency stop, speed monitoring etc.) that is already internally connected (e.g. safety PLC) usually requires for external connection following Interfaces:


Inputs

2 × potential-free for emergency stop
2 × potential-free for door circuit
1 × Input door circuit requirement
1 × input reset (optional)

Outputs

1 × emergency stop on the robot
2 × potential-free relay outputs
1 × machine door circuit open on the robot
2 × potential-free relay outputs
1 × machine in basic position
1 × info door 2 open/closed on the Robot



processing machine

Safety Simplifier | S16LDRB-H10-Q1A-Q2A-Q3A-Q4A | SP-X-89-000-03




Industrial robot requirements

An state-of-the-art industrial robot requires for the integration in a cell following interfaces for the safety technology (e.g. safety PLC ) Robot control cabinet


Inputs

2 × potential-free for emergency stop
2 × potential-free for door circuit/ operator protection
1 × Input door circuit requirement
(move the robot to the basic position)
1 × input reset (optional)
1 × input reset (optional)
1 × input door 2 open/closed processing machine
Outputs

2 × emergency stop on the processing machine
2 × potential-free
1 × robot in basic position, info to the door magnet
1 × robot retracted into the processing machine/robot

Robot Requirements
Safety Simplifier | S16LDRB-H10-Q1A-Q2A-Q3A-Q4A | SP-X-89-000-03

Requirements safety switch protective enclosure

In order to protect the robot cell, a safety switch with a minimum performance level PLd acc. to EN ISO 13849-1 is required. In case that the robot cell has a complex design, the safety switch must be additionally equipped with an escape release. The safety switch tGard selected in the example meets the above mentioned requirements and can be optionally extended with an escape release. The M12 12-pin male connector makes it easy to connect with the Safety Simplifier.

Safety switch with guard locking (PLd) at the service door
safety switch guard lock
Safety Simplifier| S14LDRB-H0A-E2-I1-I1-I1-Q1A-Q2A-Q3C-Q4J-W16 | SP-X-89-000-56
tGard Sicherheitsschalter| THM-SMDU-QM | ITM-00159181


Immense saving of time
Estimated effort for wiring Control cabinet

0 Minuten Control cabinet (no longer necessary)
5 Minutes Service door safety switch to Safety Simplifier
30 Minutes Safety Simplifier S1 installation and wiring to the processing machine
30 Minutes Safety Simplifier S2 installation and wiring to the Robot
30 Minutes Safety Simplifier S3 voltage supply cable Routing
95 Minutes Overall effort for wiring and cable Routing