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Scalable solutions for safe positioning and motion

Scalable solutions for safe positioning and motion

In an increasingly competitive global  marketplace, a key challenge is to marry the need for assured safety with simple integration and the need for maximum machine availability. These might seem like conflicting requirements; to address them, perfect safety has to be more than just a product.

Very few manufacturers today can enjoy the luxury of working in niche markets with very little competition, or to ignore the possibilities of export to far flung corners of the world. This puts an emphasis on areas such as ease of integration, simple programming, modular design and of course the need to address increasingly stringent safety standards.

Addressing these requirements, Kübler - represented in the UK by OEM_Automatic - has a wealth of practical experience in safety issues, and a broad product portfolio to address even the most demanding safety applications. This expertise extends from a new range of safety modules to established and growing ranges of SIL2 and SIL3 certified encoders.

Kübler Safety-M modules extend from the Safety-M Compact for clearly defined standalone safety applications right up to modular devices that make even the most complex automation tasks easy to solve. Safety-M is readily scalable, and therefore perfect for applications that have to grow from one machine evolution to the next, or as installed machines

are upgraded and modified over their operational lifetime. These solutions don't only define the highest levels of safety; they also contribute to maximum machine availability.

The basic module of the Safety-M compact series is a complete speed monitoring device requiring a minimum of space. The removable operating and diagnostic display enables easy parameter setting. The safe inputs and outputs and the integrated signal splitter allow its integration in existing safety circuits.

Simple retrofitting of safety technology is a key issue, especially for older machines which have to undergo important modifications to meet the requirements of Machinery Directive 2006/42/EC. In cost-sensitive plants, in addition to the easy retrofitting, the economic aspect of a high-quality speed monitoring device also plays an important role.

Safety-M addresses these requirements. The integrated signal splitter for the encoder signals saves expensive and complex external wiring. Moreover, the easy forwarding to a control system or frequency converter is ensured.

In terms of functional safety, the device firmware integrates comprehensive speed and position-related safety functions for drive monitoring according to EN 61800-5-2. The extensive diagnostic function integrated in the firmware allows makes it possible to achieve SIL3/PLe with a certified encoder. As a modular system, the basic Safety-M module can be expanded with a range of axis expansion modules and safe I/O expansion modules. The axis expansion modules can be connected to incremental or absolute encoders, and up to two axes can be monitored by one module.

Teach-in of the speed is possible thanks to a front-side button. The setting of machine parameters is simplified, as no conversion of gear factors or gear ratios is required. The expansion modules with safe I/O are suitable for connecting safe sensors such as light barriers, laser scanners and emergency stop switches.

The Kübler safety offering is completed by a wide range of encoders. Kübler Sendix SSI/BiSS absolute encoders and Sendix incremental encoders in Sin/Cos version are now available with SIL3/PLe certification, and complemement the Safety-M modules perfectly in the implementation of flexible, intelligent functional safety systems. In operation, Sendix SIL absolute encoders obtain safe information about the absolute position; the controller counts the incremental pulses and compares the result with the absolute position, which has also been provided by the same encoder. With Sendix SIL incremental encoders, the controller monitors the validity of the analogue, 90° phase-shifted sine/cosine signals with the help of the function sin_+cos_=1.

To ensure the highest level of integrity in safety applications, the Sendix SIL encoders feature a rugged, reliable interface and a safe mechanical connection, providing the ability to withstand high mechanical and electrical loads. The result is a very high degree of accuracy and a long service life. At the same time, thanks to IP67 protection and magnetic insensitivity, the Sendix SIL encoders deliver on the promise of all-round safety.

With its broad product range and deep safety knowledge, Kübler is able to address the disparate safety requirements of many different applications, providing the most appropriate safety solution rather than taking a one-size-fits-all approach. Whether the project is a new installation or a machine retrofit, Safety-M modules and Sendix SIL encoders can be combined to offer a safe motion and/or safe positioning solution that assures highest levels of operational safety whilst ensuring maximum machine availability.

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