Implementation of a robotic cell with the Safety Simplifier

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.

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

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

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

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

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

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.

Machine Requirements

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

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

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

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