Bet on the Right Card

Machine Safety Bet on the Right Card

2026-02-02 From Schmersal | Translated by AI 5 min Reading Time

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The operators of Tiepner machines are always well informed about the operating status in the safety circuit. This is ensured by illuminated door handles and a safety field box from Schmersal on the company's latest machine.

Tiepner's compact system produces ID cards made of laminated plastic, which are used as customer cards, ID cards or cheque cards, among other things. Left in the picture: Christian Höltge, Managing Director of Tiepner GmbH.(Image: Tiepner GmbH) — Tiepner's compact system produces ID cards made of laminated plastic, which are used as customer cards, ID cards or cheque cards, among other things. Left in the picture: Christian Höltge, Managing Director of Tiepner GmbH.
(Image: Tiepner GmbH)

The customers of Tiepner GmbH in Germany do not put all their eggs in one basket. On the contrary: with a single Tiepner system, they produce or process a five-digit number of plastic cards per hour, which are used universally as ID, chip, ID card, cheque or customer cards and are made of different plastics - mostly PVC or polycarbonate.

Recently, Tiepner designed, built, and delivered such a system that fully automates the production of cards in the standard ID format (see image 1). The raw material consists of laminated sheets fed into the system. At various stations, the sheets are first separated, then aligned, and their thickness is checked. This is followed by a station that punches out three cards with standardized dimensions from the base material. The individual cards are stored in one of several magazines. In this way, the system produces around 15,000 cards per hour—with or without a chip, in series or personalized.

Gallery

The door handles can be combined as a modular unit with the compact safety lock AZM40. (Source: Tiepner GmbH)

A separate control panel from the BDF 100 series by Schmersal is used for additional operating functions (shown above in the image). (Source: Tiepner GmbH)

The separate emergency stop button, also from the BDF 100 series by Schmersal, is installed in a location where it is quickly accessible and within view in case of an emergency. (Source: Tiepner GmbH)

The Safety Fieldbox from Schmersal simplifies the integration of safety switchgear into the safety circuit. (Source: Tiepner GmbH)

Gallery with 6 images

Aside from the removal of the magazines, the machine operates automatically, meaning that an operator does not have to intervene in the literal sense. The operators have a clear view of each individual station, and the safety doors—with large viewing windows—are secured by a safety lock.

New Operating System

This concept is standard across all Tiepner machines, as is the fact that the safety switchgear and operating devices at the safety doors are sourced from Schmersal. In the case of the latest system presented here, Tiepner was among the first users of a new generation of operating systems. Managing Director Christian Höltge stated: "Just before we started the construction of this custom machine, Schmersal introduced a new series of door handles with illuminated grips that signal the operational status of the machine. Since we place a high value on transparency at the human-machine interface, we were immediately drawn to this series. It fits well into our operating concept."

The new series features the DHS door handle system, which combines the functions of a robust door handle with the display of various machine states: the door handles illuminate extensively in up to seven colors. Users can configure the association of color and function themselves. Tiepner uses the system, among other things, to signal whether the safety door can be opened. If the control system detects an irregularity, the door where the issue was identified will be highlighted by color.

Additionally, each door handle in the DHS series is equipped with a pushbutton, the function of which can also be freely assigned—for example, a reset function or a request to open the safety door.

Transparency at the Safety Door

From the user's perspective, the door handle system simplifies the operation of the machine. The user knows where things stand—for example, in which operating mode (setup or tip operation) the machine is currently operating. As Tiepner has configured the system, the user can also inquire via the pushbutton whether the safety lock has released the door, meaning if it can be opened. This eliminates the need for additional door handles and indicator lights.

The entire door handle system is designed for integration into 40-mm profile systems (~1.6 inches)—and it can be used as a modular unit with the safety lock AZM40. Tiepner utilizes this combination, thereby realizing the central functions of machine safety and the human-machine interface—position monitoring of the safety door, locking/engaging/opening of the safety door, and information about the operational status—in a compact unit.

Combination with Compact Safety Lock

With this new system, the designers at Tiepner and the users of the first machine equipped with it are completely satisfied. Christian Höltge states: "The operator is always well informed: Can the safety door be opened? At which door did the control system detect an irregularity? This creates transparency."

For additional operating functions, a separate control panel from the BDF 100 series by Schmersal is used. They can be installed with minimal effort in locations where they can be quickly accessed if needed—also serving as a separate emergency stop button. Furthermore, they are very compact and fit perfectly with the 40 mm (~1.6 inches) profiles of the machine enclosure.

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Tiepner is also utilizing the Safety Fieldbox from Schmersal on the level of safety-related communication—this being its first use as well. Through the universal device interfaces for eight-pole M12 connectors, electronic and electromechanical safety locks, sensors, control panels, light curtains, or switches can be integrated into the safety circuit. Safety locks and safety light barriers require only one M12 connector slot.

Transmission via Secure Ethernet Protocol

Control panels with emergency stop functions, as well as up to three non-secure command and signaling devices, can be connected directly to a port on the Safety Fieldbox without the need for additional hardware. Data is transmitted to the control system via a secure Ethernet protocol. This creates a solid foundation for the modularization of safety technology—also from a cost perspective, as this universal device interface is more economical than individual devices with bus interfaces. For larger systems, multiple interconnected field boxes could also simplify safety-related communication.

For Tiepner, the installation of safety switchgear for this system was particularly straightforward. Christian Höltge stated, "When placing the order, we specified the cable lengths, and Schmersal supplied the pre-assembled cables along with it. This saved additional time, and the installation of the field box itself required very little effort."

Specialist in ID Card Production

Tiepner also designs and manufactures (significantly larger) systems than the one described here. These systems are used to produce the layered material from which the cards are punched. Up to eight sheets of polycarbonate or PVC as sheet or roll material are first prepared individually (and of course fully automatically), trimmed if necessary, and then stacked. Cameras assist in the stacking process, where precise alignment of the printing is also crucial. This is followed by the punching of the individual cards. Specifically for this operation, Tiepner manufactures separate and extremely compact machines, as described here.

Complete Solution for Machine Safety

Thus, Tiepner has not only relied on a complete solution for machine safety from Schmersal in the design and manufacture of this machine—this is standard practice. The specialist in the production of plastic ID cards utilizes a new product from Schmersal, the DHS series, which provides transparency at the safety door, and the Safety Fieldbox simplifies communication within the safety circuit as well as the installation of safety switchgear. In doing so, Tiepner is betting on the right card in terms of machine safety: the company is open to innovations in both the control elements and safety-related communication.