Industrial Revolutions. Smart Industry / Industry 4.0

Transcription

1 Industrial Revolutions Smart Industry / Industry 4.0

2 A simple concept for complex automation

3

4 BENEFITS CONCEPT Savings of time and money Fast connection due to M12-connectors Connecting instead of wiring Avoiding of connection failures No expert stuff necessary New options Easy duplicating of (PLC) projects in series machine manufacturing Pre- wiring of machine segments Elimination of parallel wiring and cabinet volume (safety relays) Reduction of the IP address range Short downtimes by easy component exchange Field devices: M12-connections Standardized wiring concept acc. to AIDA Safety hub and master: mechanisms of the PLC Little effort for changes by using existing IO-Link topology IO-Link with standard master Scalable 1 to X devices, Automation and Safety mixed

5 ENHANCING THE IO-LINK

6 SYSTEM DESCRIPTION World s first combination of IO-Link and Safety Communication via one Topology Open System on the sensor level Connection of the safety IO-Link device to the standard Balluff IO-Link-Master Parameterization via PLC

7 SYSTEM HISTORY until so far now

8 "TUNNELING" Ensure the safe communication Communication between the safe end points via tunneling (Black-Channel- Principle) In a network "tunneling" means to allow a foreign protocol to run over a network that does not support that particular protocol. Tunneling involves repackaging the data into a different form. (here: Profisafe over IO-Link)

9 APPLICATION EXAMPLES SYSTEM Risks at the machine must be assessed (machinery directive) Hazards must be eliminated or reduced to a societally justifiable risk Risk reductions are normally realized by complementary protective measures New: the communication is now via IO-Link

10 PRODUCT DETAILS SYSTEM minimum configuration F-CPU (e.g. Siemens) Profisafe Balluff Profinet-Master BNI PNT Guard locking device BID F101 Safety light curtain BLG 4A Power supply e.g. BAE PS safety I/O device BNI IOF Interlocking device BID F101 E-Stop BAM ES

11 APPLICATION EXAMPLES SAFE I/O DEVICE Safety device for the safety tasks in the field Transmitting the safety information via IO-Link up to the safety PLC This device is connected to a Master device in accordance to the IO-Link topology Standard safety devices (E-Stop, Safety Switches, Safety Light Curtains, Safety Sensors ) are connected to this safe I/O device.

12 PRODUCT DETAILS SAFE I/O DEVICE Further features Profisafe over IO-Link & PLe / SIL CL 3 standardized wiring concept (AIDA) Diagnostic and Display integrated CE, TÜV, (UL in preparation) technical data (extract) Cycle time: 20 ms Temperature range: -5 C 55 C Inputs: 2 pcs. Safe Inputs: 12 pcs. Outputs: 2 pcs. Safe Outputs: 2 pcs. Sum current (Aktors): 8 A Sum current (Sensors): 4,8 A

13 PRODUCT DETAILS SAFE I/O DEVICE Cable length IO-Link: max. 20 m (acc. IO-Link Specification) Cable length U B : max. 30 m Cable length Device: max. 30 m (s. Specification Device)

14 CONNECTION CABLE (5-PIN) MECHANICAL SWITCHES Device Female A Coloring Male B BCC M415-M415-3A-312-PX4534-###-C033 BCC M415-M425-3A-312-PX4534-###-C033 ### = cable length in dm

15 CONNECTION CABLE (5-PIN) OSSD SENSORS Device Female A Coloring Male B BCC M415-M414-3A-304-PX0434-###-C033 BCC M415-M424-3A-304-PX0434-###-C033 ### = cable length in dm

16 CONNECTION CABLE (5-PIN) ACTUATORS Device Female A Coloring Male B BCC M415-M415-3A-313-PX0534-### ### = cable length in dm

17 CONNECTION CABLE (8-PIN) MECHANICAL SWITCHES Device Female A Coloring Male B BCC M418-M418-3A-320-PX4825-###-C033 BCC M418-M428-3A-320-PX4825-###-C033 ### = cable length in dm

18 APPLICATION EXAMPLES E-STOP Every machine must be equipped with min. one E-Stop device, to enable actual or impending danger to be averted. Exception: Machines where a E-Stop device the Risk my no reduce hand-held and/or hand operated machines extract machine directive 95/16/EG

19 PRODUCT DETAILS E-STOP Feature Complete device (enclosure device) pluggable version IP65 CE, TÜV, UL (in preparation) technical data (extract) Reset: Turning Temperature range: -25 C 75 C Safety Contacts: 2 pcs. B10d: switching cycles

20 APPLICATION EXAMPLES INTERLOCKING DEVICE Prevents hazardous machine functions as long as the safety guard is open Trigger a stop command if the safety guard (door) will be opened. Overall stopping time < access time EN ISO 12100

21 PRODUCT DETAILS INTERLOCKING DEVICE Features Strong metal housing Status LED IP65 CE, TÜV, cnrtlus technical data (extract) Guard locking: No Temperature range: -0 C 40 C Safety contacts (door): 2 pcs. Aux contact (door): 1 pcs. B10d: switching cycle LED: red

22 APPLICATION EXAMPLES GUARD LOCKING DEVICE Keeps a safety guard (door ) in closed position until risk is eliminated Hazardous machine functions are enabled when the protected guard (door) is closed and locked. overall stopping time > Access time or for process safety purposes EN ISO 12100

23 PRODUCT DETAILS GUARD LOCKING DEVICE 1/3 Feature Strong metal housing with solenoid optional escape release Status LED IP65 CE, TÜV, cnrtlus technical data (extract) Guard locking: Yes (locking force: N) mechanical BID F101-2M1M3.- electrical BID F101-2M1E3.- Temperature range: -0 C 40 C Safety contacts (guard locking): 2 pcs. Aux contact (door): 1 pcs. B10d: switching cycle LED: red/green

24 PRODUCT DETAILS GUARD LOCKING DEVICE 2/3 Order code Type Locking Auxilliary release Escape release Connection Image BID0001 BID F101-2M1E3R-M02AZ0-S115 Electrical No Yes M12 (8-pin) BID0002 BID F101-2M1M3R-M02AZ0-S115 Mechanical Yes Yes M12 (8-pin) BID0003 BID F101-2M1E3-M02AZ0-S115 Electrical No No M12 (8-pin) BID0004 BID F101-2M1M3-M02AZ0-S115 Mechanical Yes No M12 (8-pin) BID0005 BID F101-2M100-M20ZZ0-S92 No - - M12 (5-pin)

25 PRODUCT DETAILS GUARD LOCKING DEVICE 2/3 Guard locking (solenoid) mechanical (closed-circuit principle) - power to unlock electrical (open-circuit principle) - power to lock Auxiliary release (for mechanical guard locking devices) Possibility to unlock the device manually with a key from outside. The device will be unlocked immediately by turning the key the button and a stop signal is triggered. Escape release (for guard locking devices) Possibility to unlock the device manually without tools from inside the machine. The device will be unlocked immediately by pressing the button and a stop signal is triggered. Adjusting the actuator head Remove the screws on the housing completely. Rotate the actuator head in the requested position (90 -steps). Fix actuator head with screws again.

26 APPLICATION EXAMPLES SAFETY LIGHT CURTAIN Space-saving alternative in comparison to a safety guard Allows a direct interaction with the machine Hand working place Special functions can be realized via the control logic Material feeding (Muting)

27 PRODUCT DETAILS SAFETY LIGHT CURTAIN (FINGER PROTECTION) Feature slim aluminum profile housing PLe / SIL CL 3 OSSD switching output IP65 CE, TÜV, culus Listed technical data (extract) Resolution: 14 mm (finger protection) Protection height: 15 cm to 180 cm max. distance: 6 m Response time: s. data sheet / manual Temperature range: 0 C 55 C Connection: Plug connector M12 Emitter (4-pin) Receiver (5-pin)

28 PRODUCT DETAILS SAFETY LIGHT CURTAIN (HAND PROTECTION) Feature slim aluminum profile housing PLe / SIL CL 3 OSSD switching output IP65 CE, TÜV, culus Listed technical data (extract) Resolution: 30 mm (hand protection) Protection height: 15 cm to 180 cm max. distance : 19 m Response time: s. data sheet / manual Temperature range: 0 C 55 C Connection : Plug connector M12 Emitter (4-pin) Receiver (5-pin)

29 PRODUCT DETAILS SAFETY LIGHT CURTAIN (BODY PROTECTION) Feature slim aluminum profile housing PLe / SIL CL 3 OSSD switching output IP65 CE, TÜV, culus Listed technical data (extract) Resolution: mm (body protection) Protection height: 50, 80, 90 and 120 cm max. distance : 50 m Response time: s. data sheet / manual Temperature range: -10 C 55 C Connection : Plug connector M12 Emitter (4-pin) Receiver (5-pin)

30 EXTENDED FUNCTIONS LIGHT CURTAIN MUTING Short-term, automatic override of the safety function of the light curtain during operation Sensors are used to initiate the muting. This sensors must not be safe ones. By arranging the sensors a distinction is made between sequential (A) and cross muting (B). pre-existing function blocks in the control offers flexibility and facilitates the realization of muting there also high-priced advanced light curtains available in the market with integrated muting function A B

31 EXTENDED FUNCTIONS LIGHT CURTAIN BLANKING not possible with the BLG 4A-range today!! fixed blanking Permanent blank out of individual light beams of the light curtain this function must be set-up directly on the light curtain (programming, dipswitches, ) floating blanking toleration of damped light beams within a specified frame this function must be set-up directly on the light curtain (programming, dipswitches, )

32 SYSTEM OVERVIEW COMPONENTS System Product overview Pos. Product 1 F-CPU 2 Power supply 3 IO-Link Master 4 Connector (BK/BK) Power 5 Connecting cable (GN) PNT 6 BNI IOF 7 Connecting cable (BK/BK) Power 8 Connecting cable (BK/BK) IO-Link 9 Accessory BNI IOF 10 E-Stop (BAM ES) 11 Interlocking device (BID 0 ) 12 Accessory BID 13 Connecting cable (YE/YE) 5-wire 14 Safety Light Curtain (BLG 4A) 15 Accessory BLG 4A (Mounting) 16 Accessory BLG 4A (Floor stand/mirror) 17 Accessory BLG 4A (Wiring) 18 Connecting cable (YE/BK) 4-wire 19 Guard locking device (BID 3 ) 20 Connector (YE/YE) 8-wire 21 Connecting cable (YE/YE) 8-wire 22 Connecting cable (BKBK) 5-wire 23 Valve manifold connector 24 Smart-Light 25 Connecting cable (BK/BL) IO-Link 3-wire

33 The Benefits

34 Installation Benefits Standard-Installation - Variety of cables - High installation effort - Multiple analog and digital interfaces - Signal interference Networking - More network nodes - Additional hardware costs / sensor Cable Track Apps - Multiple- / special cables - High filling degree - Lower cable life expectancy - Higher weight / low dynamics - 3-wire non-shielded standard cable - SIO- / IO-Link modes - 24 V digital signal - No interference - IO-link port Networking - Fewer network nodes - Sensor connected via low cost hub to node. - Overall cost reduction Cable Track Apps - Less cables, thinner cable - Higher cable life expectancy - Less weight / high dynamics 5 Nodes (5 chipsets) 1 Node (1 chipset)

35 Parameterization Benefits of IO-Link Parameterization benefits : Central configuration data / device parameter storage by remote controls. Automatic parameter / configuration data transfer to device upon detection. Minimum machine down-times. Remote inspection switching / batch change Parameterization with IO-Link quick, simple, error-free, economical

36 Diagnostics: centralized access without additional wiring IO-Link gives you centralized access to detailed diagnosis and maintenance information. Benefits of : Remote access to diagnostic information of sensors and actuators No additional wiring required Error pinpointing all the way down to the sensor level Service is conducted need-based, reducing machine downtime Increased reliability and operational availability Examples for diagnostic messages: Device malfunction, contamination, under-voltage, pressure loss, overheating, etc. Cable break (loss of communication)

37 SAFETY HUB HARDWARE CONFIGURATION TIA V13

38 SAFETY HUB HARDWARE CONFIGURATION TIA V13 Download the GSD- File that belongs to the Profinet IO-Link master from the Balluff homepage Install this GSD-file into TIA Protal

39 SAFETY HUB HARDWARE CONFIGURATION TIA V13 Choose the correct GSD-file from the hardware catalogue and insert it into the network view

40 SAFETY HUB HARDWARE CONFIGURATION TIA V13 Connect the IO-Link master with the Profinet fieldbus

41 SAFETY HUB HARDWARE CONFIGURATION TIA V13 Change to device view Select the Profinet Master Assign a name to the Profinet Master

42 SAFETY HUB HARDWARE CONFIGURATION TIA V13 Select the first row "Standard I/O_1" and delete this row From the hardware catalogue insert the safety hub and drag this item into the empty line

43 SAFETY HUB HARDWARE CONFIGURATION TIA V13 Fill out the correct properties and functionality of the safety M12 ports

44 SAFETY HUB HARDWARE CONFIGURATION TIA V13 Fill out the desired safety address of the safety module Fill out the same address into the module display using the push buttons

45 SAFETY HUB HARDWARE CONFIGURATION TIA V13 Select the row with the safety module and right click this line. Select the option "Start device tool"

46 SAFETY HUB HARDWARE CONFIGURATION TIA V13 Check the parameters and confirm this by pressing the confirm button Select the checksum after the 0x and copy this

47 SAFETY HUB HARDWARE CONFIGURATION TIA V13 Go back to the device view Paste the copied checksum into the F_iPar_CRC line. Save the project and download it into the PLC After a change of e.g. the safety address or another parameter a new safety checksum has to be calculated

48 SAFETY HUB REINTEGRATION TIA V13 For every safety module a function block is generated This function block shows the state of the safety device In case of wiring or communication errors the module will switch to a safe state When the error is resolved and acknowledged, the processdata becomes available again Acknowledge request: ACK_REQ Acknowledge: ACK_REI (acknowledge for reintegration)