Safety net

Machine safety Safety net

2024-12-11 From Michael Flesch | Translated by AI 5 min Reading Time

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Turck's networked safety platform based on the Safe Link protocol and safe Ethernet multiprotocol I/O modules allows efficient and flexible safety solutions for small to medium-sized plants—up to ATEX Zone 2/22.

Assembly cells like these can be secured efficiently and reliably with Turck's Safe Link modules.(Image: Turck) — Assembly cells like these can be secured efficiently and reliably with Turck's Safe Link modules.
(Image: Turck)

Michael Flesch is the Product Manager for Safety Systems at Turck

Machine safety plays a central role in modern industrial environments and encompasses a variety of technologies and measures aimed at preventing accidents and injuries. In an increasingly complex industrial landscape, it is crucial that safety devices work not in isolation but in an integrated and networked manner. For example, a safety light curtain can immediately stop a production line if an employee enters a danger zone, while simultaneously activating an emergency stop system to halt nearby machines. This coordinated communication between safety components creates a comprehensive safety net that not only ensures the safety of employees but also maximizes machine uptime.

Safety devices must be reliable

In practice, this means that an operator working on a punch press, for example, can rely on not only the machine itself but also all conveyor belts and feeder systems in the entire area being immediately stopped when the safety curtain is triggered. This integrated response not only prevents injuries but also minimizes the risk of machine damage from the sudden stopping of isolated parts of the system. Another example is a robotic arm in a production line: if a safety laser detects that an employee is moving too close to the robot's work area, not only is the robot stopped, but also all machines interacting with the robot. This ensures that the entire area is safe and that no isolated system part continues to operate uncontrolled.

Gallery

The safe block I/O modules TBEN-LL-4FDI-4FDX from Turck offer flexible and decentralized safety control without the need for central control cabinets.(Image: Turck)

The Safety Configurator allows easy configuration of the safety modules.(Image: Turck)

The increasing complexity of industrial environments demands integrated and networked safety solutions. Particularly in small to medium-sized facilities with a moderate number of safety applications, users often face specific challenges. Another critical issue is the lack of flexibility of conventional solutions in dynamic production environments. Production lines that are regularly retooled require scalable safety solutions. Traditional, centralized safety controls are often oversized for these applications and come with high acquisition and operating costs. Additionally, there is a significant wiring effort and the complexity of installing central PLC systems. Adjustments to changing production requirements or expansions of the facility are often expensive and difficult to implement with centralized safety solutions.

Thanks to their Safe-Link protocol, Turck's safe multiprotocol I/O modules TBEN-LL-4FDI-4FDX can securely communicate with each other and with other devices in the network. This networking enables a coordinated response to safety-critical events across the entire production line. For example, a module receiving an emergency stop signal can immediately forward this information to all other modules, ensuring that all affected machines are stopped immediately. This not only ensures the safety of employees but also minimizes the risk of machine damage and production downtime. The ability for real-time communication between the modules ensures that safety measures are always synchronized, particularly fast, and therefore efficient.

Decentralized installation

The decentralized installation of the safe TBEN modules offers significant advantages, especially in smaller production lines where space and cabling effort are often issues. The IP67 modules can be installed directly at the machines where safety functions are needed. This reduces the need for central control cabinets as well as the cabling effort, simplifying installation as well as maintenance and expansion of the systems. The modules provide a direct connection via M12-L-coded power supply connectors and M12-D-coded Ethernet connectors for reliable network communication. This allows safety-related functions to be placed directly at the source, significantly increasing the flexibility and efficiency of the production line, as short paths for safety signals enable faster cycle times.

A special feature of the multiprotocol I/O modules TBEN-LL-4FDI-4FDX is their variability: Each module can be added, removed, or exchanged independently, allowing quick adaptation to changing production requirements. The ability to network up to 31 modules in one application offers considerable flexibility in designing and expanding safety solutions. In addition, each module provides 127 diagnostic bytes for monitoring and quick fault diagnosis, further enhancing operational safety. Each module offers two bytes of safety-related input and output data as well as two bytes of non-safe fieldbus bits that can be used for communication with a non-safe PLC. The integration of single and dual-channel inputs as well as safe outputs, which can be used directly to control machines and drives, allows for seamless integration of the modules into existing safety networks. This scalability enables companies to respond flexibly to market demands and technological developments without having to invest in rigid and cost-intensive safety solutions.

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Seamless integration through multiprotocol

The safe multiprotocol TBEN modules support a variety of communication protocols, including Ethernet/IP, Profinet, and Modbus TCP, as well as the safety protocols CIP Safety and Profisafe. Thanks to this capability, companies can maintain their existing network infrastructure while integrating the new safety modules, saving time and costs. This versatility makes the modules particularly attractive for companies operating in heterogeneous system landscapes that require a unified, flexible safety solution.

Foreign objects in the field can be better detected by radar than by alternative technologies. (Image:Hans Turck GmbH & Co. KG)

For applications in explosive areas, the multiprotocol I/O modules offer a decisive advantage with their ATEX certification for Zone 2/22. This certification ensures that the safety solutions operate reliably even under extreme conditions and comply with legal regulations. By using these modules in explosive environments, companies can ensure that their employees and equipment are optimally protected, significantly expanding operational possibilities and providing additional flexibility in sensitive areas.

Efficient and economical safety platform

The integration of Turck Safe Link into the safe multiprotocol I/O modules TBEN-LL-4FDI-4FDX enables companies—especially in small to medium-sized facilities—to implement a flexible, scalable, and cost-efficient safety solution, even in ATEX Zone 2/22. The decentralized IP67 concept allows for a tailored adaptation to individual requirements, while the multiprotocol capability facilitates integration into existing systems. With the capacity to network up to 31 modules and integrated diagnostic functions that allow for quick fault detection, this solution offers high scalability and operational safety. Overall, the TBEN modules represent an efficient and economical safety platform that not only provides the highest safety standards but also contributes to maximizing uptime and minimizing machine damage.