PRODUCTS & APPLICATIONS. Application guide Flexi Soft. Applications of the modular safety controller Flexi Soft at machines and installations

Transcription

1 PRODUCTS & APPLICATIONS Application guide Flexi Soft Applications of the modular safety controller Flexi Soft at machines and installations

2 safetyplus we solve safety problems Safety solutions from SICK increase your security of investment, open up new potential for savings due to more effi cient processes, and always remain focused on the primary objective the safety of man and machine. Rock-solid safety concepts for perfect operational safety safetyplus provides a unique range of competencies for the safety of man and machine. After all SICK is the world s leading manufacturer of industrial safety systems and convinces with an impressive combination of competence, products and services. Water-tight system solutions for complete safety applications Behind safetyplus is the world s most versatile product portfolio: A comprehensive safety package from safety switches through optoelectronic sensors to safe control solutions and networks. Simple and trouble-free in application from planning to worldwide usage. 3 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

3 Unlimited potential for savings due to integrated safety concepts The unique cost-effectiveness of safetyplus saves time and money! This starts with the uncomplicated planning and carries on through installation and commissioning to the actual production. Every SICK technology is as easy as possible to use and will also be up to date in fi ve years time. Complete safety by means of services for every day The safetyplus services: SICK experts advise and assist from the fi rst plant walk-through, during the risk assessment and all the way to the CE assessment - always compliant with the latest standards and directives, and with the SICK inspection seal for machinery and systems. By the way: Every year SICK performs more than 10,000 safety inspections worldwide / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 4

4 Further informations: Product information Data sheet Service you can depend on With SICK you will always obtain optimal results in the interaction between man and machine. With SICK you have, in this sensitive area, a partner at your side whose innovations have been setting international standards for more than 60 years; most recently with safetyplus, the all-round package for industrial safety. CE certification Plant walk-through switches Enabling S200 switches pull Rope S300 scanner Safety stop Emergency pushbuttons system S3000 Outdoor Safety safety command Safety devices laser systems S100 V200 Station Work scanners V300 Station Work Laser V4000 scanners Safety camera LGT systems C2000 C4000 Safety devices protective Opto-electronic switches Safety light curtains M2000 M4000 Multiple beam light safety devices Industrial Safety Systems Safety ware L2000 WSU/WEU26-2 L4000 Single-beam photoelectric safety switches licence Safexpert Safexpert Services & Support standards of Package StandardManager versions assistant instructions Operating acceptance and Check Compliance & Design contracts update and Service assistant Risk assessment Measurements Verification & Education Safety concept Training & Hardware design Project management Investigation investigation Accident equipment check Seminars Electrical Software design User training Inspection Installation inspection WebTraining Functional safety assessment Commissioning Machine safety Stoptime measurement Stoptime measurement CE-conformance check Noise measurement Noice measurement switches safety Inductive switches safety Transponder switches safety Magnetic Non-contact switches safety actuator separate with Safety switches devices Safety locking Safety switches position Safety hinge switches switches safety Electro-mechanical Safety relays Safety relays UE10 - UE48 Muting module UE49 soft- sens:control safe control solutions Safety controllers Modular safety controllers Compact safety controllers Flexible safety controller Safety remote controllers Network solutions PROFIsafe services AS-Interface Upgrade Safety at Work DeviceNet Safety Gateways EFI gateways upgrade kit PLS/S3000 Diagnostic tools support upgrade kit Product LCUR1-411 Workshop repairs Exchange units Spare parts Service tools Helpline support On-site troubleshooting 2 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

5 Application guide - Flexi Soft Page Overview page SafetyPLUS we solve safety problems 3 Your advantages explained simply 6 Flexi Soft Modular safety controller with a powerful software 8 Overview of Modules 10 Applications in detail 1) Fishing boat 12 AGV 13 Wood scanner 14 Robot welding cell 15 Material loading of a vertical panel saw 16 Automated guided system in a logistics center 18 Leak detection at fuel tanks 20 Double cell welding robot 22 Stretch film winder 24 Pneumatic press 26 Tyre fabric winder 28 Newspaper palletizer 30 Pop-up press 32 Metal plate milling machine 34 Test machine for computer chips 36 Robot cell for kitchen door lacquering 38 Beer barrel washing plant 40 Baking station for meat loaf 42 Ordering information Ordering information 44 CD for the handbook 45 1) All applications are reference examples and has to get adapt to your special request. More safety due to customised service! / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 5

6 Your advantages explained simply sens:control - a new name for safe control solutions The new generation of safe control solutions from SICK combines advanced technologies with ease of use in every project phase. How does it work? Very simply: SICK developed, from the ground up, a new integrated product concept that was consistently designed for uncomplicated usage. A comprehensive range of engineering and services Sometimes it is a long way from planning to reality - but not with SICK! With sens:control the selection is quick and the configuration simple. In all phases of the project from planning, through commissioning to maintenance and upgrades to existing systems, we support you with comprehensive services. 6 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

7 Overview Flexi Soft Applications in detail Ordering information and CD sens:control safe control solutions for a multitude of different industries Safety and simplicity encompasses the solution for all branches and applications. The products range from making possible the simple integration of an Emergency Stop on a packaging machine, to the integration of optical safety sensors with press contacts or the combination of entry/exit stations with entry protection in a logistics centers and finally up to the networking of complex machines with one another, all with minimal engineering effort. Safety relays No logic 1-2 inputs Up to 2 x 2 outputs Central solution Safety controller Flexi Classic Safety controller Flexi Soft Simple logic with 4 types of Medium to complex logic logic function blocks with 38 logic blocks inputs 8-96 inputs 4-52 outputs 4-48 outputs Confi guration via Confi guration via screwdriver software Central solution Central solution Network solutions Medium to Complex Logic with 38 Logic Blocks >100 inputs > 48 outputs Decentral solution / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 7

8 Modular safety controller with a powerful software Flexi Soft Safety made easy Steep learning curves and complicated programming are no longer part of Machine Safety. Flexi Soft makes it so simple via the intuitive and ergonomic programming software. With the Flexi Soft Designer, the entire project is programmed from beginning to end. The planning is done via PC and hardware is selected and combined to offer the optimal amount of inputs and outputs. All tactile and optical safety sensors can be attached to these modules in order to complete the project. Up to 12 modules can be attached to the chosen CPU and thereby up to 144 inputs/outputs can be used. Due to the individual and compact 22.5 mm wide modules, the control cabinet only needs to house enough safety controller to match the application. On the next pages, the Flexi Soft Designers functions and which modules used for expansion will be described in detail. Product description Shortened response time and therefore shorter distance from the hazardous point (8 ms) using Fast Shut Off makes possible the building of more compact machines Confi guration via intuitive software with a graphical user interface Logic editor with a comprehensive library of certifi ed function blocks Function block based logic editor Optimised integration via EFI (e.g. S3000, C4000) Integration in all leading networks: EtherNet/IP, PROFIBUS-DP, CANopen, Modbus TCP, Device- Net, PROFINET IO Customer use Low I/O count per module avoids the purchase of unused inputs and outputs Confi guration in the Memory Plug for a lightning quick commissioning Intuitive software with wiring diagram and offl ine simulation Expansed sensor functionality via EFI Cost effi ciency: Shortend engineering time due to increased software ergonomics. Singlechannel outputs reach SIL3, Ple 8 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

9 Overview Flexi Soft Applications in detail Ordering information and CD Flexi Soft Designer Hardware configuration Simple hardware configuration by drag & drop Large selection on input and output elements with symbols that are easy to understand Customer-specfic modification of elements which can be inserted into a special library Simple transfer of elements and modules which have already been utilized Context-specific help Multi-language menu support (ie. G/En/Fr/Sp) Online monitoring of the I/Os Logic editor Comprehensive library of 38 function blocks 255 logic blocks are at the ready Special function blocks for presses and Muting applications are included I/O summary for a concise overview Offline simultation mode Force mode to easy commissioning Online monitor in the logic Report and diagnose Comprehensive report in one file Wiring diagram included Possibility to insert project description Thorough diagnostics of all parts at all times Detailed description to get to the root of the problem Presentation of the configuration in graphical form Multi-language fault text For further information and to download the designer free of charge, visit us at / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 9

10 Multifaceted Overview of Modules Main modules General function blocks (i.e. AND/OR/XOR/NOT) Application-specifi c: Bypass, Muting, Press, etc. RS-232 port for confi guration and real-time diagnostics EFI connection for expanded sensor functionality, thorough diagnostics and bidirectional device communication FX3-CPU0: without EFI connection FX3-CPU1: with 2 EFI connections Separate memory plug to save the safety controller`s confi guration In-/ Output expansion modules FX3-XTIO: Input/output expansion with 8 safety inputs, 4 safety outputs and 2 test outputs FX3-XTDI: Input expansion with 8 safety inputs and 8 test outputs Up to 12 modules can be attached to the chosen CPU and thereby up to 144 inputs/outputs can be used Relay expansion modules UE410-2RO: 2 normally open, 1 application diagnostic output and 1 EDM contact UE410-4RO: 2 x 2 normally open, 2 x 1 application diagnostic output and 2 x 1 EDM contacts UE12-2FG: 2 normally open and 1 EDM contact, cascade UE10-2FG: 2 normally open and 1 EDM contact 10 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

11 Overview Flexi Soft Applications in detail Ordering information and CD Gateways In order to connect Flexi Soft to an existing PLC, it is possible to integrate up to two Gateway. Using these gateways, I/O status as well as fault and status information can be read from and nonsafe process data can be written to the Flexi Soft. The contents of the process data can be customized and the most frequently requested data is preconfigured out of the box. The following modules are available: EtherNet/IP FX0-GENT ( ) PROFIBUS-DP FX0-GPRO ( ) CANopen FX0-GCAN ( ) Modbus TCP FX0-GMOD ( ) DeviceNet FX0-GDEV ( ) PROFINET IO FX0-GPNT ( ) Product description Diagnostic module for connecting to an existing PLC Send and receive at least 50 Bytes of information Compact 22.5 mm width Confi guration via intuitive software with a graphical user interface Shortened failure discovery Acts as a bridge between two network protocols when two gateways are used Remote diagnostics and confi guration of Flexi Soft and attached EFI sensors via the Ethernet based gateways(ethernet TCP/IP) Customer use Diagnostics show the input status (HIGH/LOW) of all Flexi Soft modules as well as EFI devices Display of logic result status within the Logic editor Default and status information of all Flexi Soft modules Diagnostic data (i.e. I/O fault messages in text format) / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 11

12 Fishing boat and AGV E-Stop centralization for motors SICK is continuously publishing examples of application solutions on the Internet On a fishing boat the winding motors which deploy and retract the fishing nets are to be fitted with E-Stops and safety switches. The monitoring of the emergency stop function will be centralized and controlled by the appropriate safety controller. Realization The emergency stop function is centralized within the Flexi Soft safety controller. There are two winding motors for fishing nets on each side of the fishing boat. In addition to the normal on/off functioning of the motors, there are two ES21 emergency stop pushbuttons and one i10 safety switch on each winding motor which minimize the danger for man and the machine. By activating the safety switch the motor will be safely shutdown. By the logical connection of the E-Stops and the safety switches associated with each side of the ship within the Flexi Soft safety controller, the emergency stop function is centralized. In order to offer the expected signal to the motors, four additional 4RORelay expansion modules are used to control them. Via a Reset button associated with each motor, the fishing net s motor is reactivated. Especially useful is that the safety solution can be quickly configured and tested offline on the desk which avoids unscheduled durability of the boat into the harbor, even if the number of motors is unknown. 12 Application at a glance Safety automation Industrial sector/branch Food & beverage Applications/type of machine Fishing boat Safety functions Emergency stop function Product family Flexi Soft, ES21, i10 Customer use Centralization of the emergency stop function Additional protection for man and machine The powerful logic editor and the modular assembly assure a fast and worry free installation The systems grows module by module with the application P R O D U C T S & A P P L I C AT I O N S A P P L I C AT I O N G U I D E F L E X I S O F T S I C K /

13 Overview Flexi Soft Applications in detail Ordering information and CD Reduced downtime for automatically guided systems In the automobile industry the workers should be protected of being hit by an automated guided vehicle (AGV) which transports motor blocks. Beside the protection by scanners, there has to be the possibility of an emergency stop. Application at a glance Industrial sector/branch Applications/type of machine Safety functions SICK is continuously publishing examples of application solutions on the Internet Safety automation, Hazardous area protection Automotive & vehicle construction AGV Emergency stop function, Reset/ Restart Realization Product family Flexi Soft, S300 Advanced, ES21 Lower downtime of an AGV can be achieved through use of safety laser scanners. The AGV has two directions of motion making two scanners necessary to avoid collisions. You can find one S300 Advanced safety laser scanner on the front and the back side of the AGV, installed just above floor level. They are connected to the Flexi Soft safety controller by the EFI interface. Their main task is the protection in each direction of motion using an protection field. Only the protection field, which heads to the direction of motion, is active and gets switched to inactive via Flexi Soft if there is an change of the direction of motion. It s thereby possible to traverse the track behind the AGV. The ES21 emergency stop pushbutton gets assembled on the Customer use top of the AGV, so that the worker Lower down time increases the availability could use it if it s necessary. There is Protection fi eld switching increase ease of human machine interaction an reset button installed, to actuate The traverse of the track is possible behind the AGV the AGV again. Due to it s small size, the safety controller easily can be positioned inside The Flexi Soft safety controller, integrated the cabinet of the AGV into the cabinet of the AGV, stops the AGV if the safety field is interrupted or the E-Stop has been pressed. Additional information on / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 13

14 Wood scanner and Robot welding cell Protection for a safe set up and servicing In a sawmill single planks are individually tested for inconsistency and are sorted out using a wood scanning machine. The wood scanner must be protected against unauthorized access during regular operation. Realization The wood scanner is surrounded by 4 access doors which are each protected by an RE300 non-contact safety switch. The wood scanner only runs if all doors are closed. If one door is opened during regular operation, a safety switch is activated and the conveyor belt and wood scanner are switched off. In order to allow for service mode, an E100 enabling switch is used. In service mode, the switch off signal is overridden by the enabling switch and quick adjustments can be made at slow speed. Additionally, three dual-channel ES21 emergency stop pushbuttons are wired in series to switch off the machine if it is necessary. All connected sensors are attached to the Flexi Soft in which the signals are combined in the logic editor to switch off the machine safely. Application at a glance Industrial sector/branch Applications/type of machine Safety functions Product family Customer use Assured service mode with an enabling switch Safe access to the machine in service mode is assured Compact safety concept for the entire machine SICK is continuously publishing examples of application solutions on the Internet Safety automation, Hazardous area protection Wood, furniture Wood scanner Emergency stop function, Safety-related stop function, Differentiation between men and material (Muting) Flexi Soft, RE300, ES21, E PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

15 Overview Flexi Soft Applications in detail Ordering information and CD Protective field switching for increasing productivity In the automotive industry two exchangeable containers are manually filled next to a welding robot. These containers can be completely removed. Therefore the aperture has to be protected against unauthorized access. Application at a glance Industrial sector/branch Applications/type of machine Safety functions SICK is continuously publishing examples of application solutions on the Internet Safety automation, Access protection, Hazardous area protection Automotive & vehicle construction Robot welding cell Differentiation between men and material (Muting), Emergency stop function Realization Product family Flexi Soft, S3000 Advanced, WT24 To increase productivity, it is necessary to install an S3000 Advanced safety laser scanner above the depot to protect the hazardous area around the robot. The EFI interface on the safety laser scanner and the Flexi Soft safety controller allow for a simultaneous protection field monitoring. Both protection fields are constantly active, except when they are disabled due to a muting condition via four WT24 sensors. This means that the wagon can enter and exit the depot without stopping the robot. If there is a person walking into the depot, the Flexi Soft safety controller detects the dangerous situation by the Muting sensors and stops the robot. Customer use The controller sees that a wagon isn t Space saving solution with only one safety laser scanner interrupting the sensor, but rather Only one safety laser scanner, because the analysis that there is a abnormal motion. The of two simultaneous fi elds via the EFI interface is possible Flexi Soft provides the interface for Increased availability thanks to the simultaneous protection fi elds the S3000s EFI communication and and muting inputs for the WT24 sensors and Muting evaluates and differentiates between man and material securely shuts down the robot in case of a danger. It controls the intrusions into both protected zones and evaluates the information from the muting sensors and S3000 to stop the robot. Additional information on active inactive / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 15

16 Material loading of a vertical panel saw Complete entry guarding of a dangerous area On a panel saw large panels out of wood and plastic get cut individual or as a package. The three entry points have to be protected because it is possible for a worker to enter the area of the saw. The access and exit, through which the panels automatically reach the machine to get cut, have to be protected. Thereby the controller has to detect if there are panels or a man entering the hazardous area. The accesses which are parallel to the conveyor belt have to be protected against unauthorised incidence while the going concern. Due to the high speed of the saw blade the trespass of the hazardous area would be especially dangerous. In case of an unauthorised switch off of the saw, a reset is required. Realization All three accesses to the machine are protected by a M4000 Advanced multiple light beam safety device. If a person or a subject reach the hazardous area, the machine switches off safely. Access to the entry and exit side of the saw s conveyor belt is additionally monintored by Muting. On either side two WT24 sensors which take over the muting are attached. There are two M4000 Advanced multiple light beam safety device located on each side as well, which are both connected to the main module of the Flexi Soft safety Application at a glance Industrial sector/branch Applications/type of machine Safety functions Product family controller via the EFI interface. If something else than a panel enters the hazardous area, the connected WT24 sensors give the information to the Flexi Soft safety controller, which in turn shuts down the machine. The controller detects, that there is no panel on the conveyor belt, but an object or a person, which isn t allowed to be there. The frontal access to the saw is protected by SICK is continuously publishing examples of application solutions on the Internet Safety automation, Access protection, Hazardous area protection Wood, furniture Vertical panel saw Differentiation between men and material (Muting), Emergency stop function Flexi Soft, M4000 Advanced, WT24 a M4000 Advanced multiple light beam safety device which is connected to the expansion module of the Flexi Soft safety controller. Muting is not needed here, as nothing must enter the machine from this side. In case of an shutdown of the saw, a manual reset on the control cabinet gets required. 16 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

17 Overview Flexi Soft Applications in detail Ordering information and CD Customer use Minimal space requirement due to the optimal use of the inputs and of the EFI interface Decrease in downtime thanks to the muting function Used modules: Main module FX3-CPU1 Expansion modules FX3-XTIO Hardware configuration The complete configuration can be found on the CD included. Used logic functions: NOT, AND, OR, EXOR Reset Switch On Delay Switch Off Delay Edge Detection 2 Sensor Muting RS Flipflop Interlock Monitoring In/Out Summary Page The description of how the used logic blocks work is found in the Flexi Soft Designer Software Users Manual( ). Additional information on / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 17

18 Automated guided system in a logistics center Increased productivity via manual and automatic restart An automated guided vehicle (AGV) on rails transports pallets from the palletizer to the packaging machine. The area around the rails is constantly traversed by the workers. For this reason the use of a conveyor belt wouldn t be possible. To avoid a collision between the AGV and a worker or to eliminate the negligent use of the AGV as a personal means of transport, the AGV has to be protected. If a worker climbs on the AGV, there must be an manual restart. Also the AGV has to stop, if any worker enters the hazardous area around the AGV. By leaving the hazardous area there will be a Restart after 2 sec, to avoid long downtimes. The palletizing machine and the packaging machine have also to be secured against unauthorized access. Application at a glance Industrial sector/branch Applications/type of machine Safety functions Product family SICK is continuously publishing examples of application solutions on the Internet Safety automation, Hazardous area protection Logistics AGV Emergency stop function, Differentiation between men and material (Muting) Flexi Soft, S3000, S300, M4000, ES21 Logi Realization The hazardous area around the AGV is protected by two S300 safety laser scanners, one on the left and one on the right side and two S3000 safety laser scanners, one at the front and one at the back side. The two safety laser scanners S3000 are connected to the Flexi Soft safety controller by the EFI interface. The two S300s are connected to the expansion module of the Flexi Soft. The simultaneous protection field detection offers an extra level of safety for the workers. By entering the large protective field of the S3000 the AGV brought to a stop, however after two seconds there is an automatic Restart. If the smaller protection field of the S3000 is then interrupted, the AGV stops again but has to be restarted by a manual Reset as the worker is now too close to the AGV. To either side of the AGV, a protective field of the S300 protects the area. Noone can enter the AGV and thereby enter the machine without tripping a field. The protection fields of the four safety laser scanners are active all the time, independent of which direction the AGV is heading. Finally, to stop the AGV in a hazardous situation there is an ES21 emergency stop push button on the AGV. The protection of the entry to the palletizer is achieved through a separate safety controller in conjunction with a M4000 multiple light beam safety device. Additional two WL24 sensors are installed with their reflectors for the muting. 18 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

19 Overview Flexi Soft Applications in detail Ordering information and CD Customer use Simultaneous protection fi eld analysis via the EFI interface allows for an automatic and manual Restart depending on the situation Minimized downtimes of the AGV thanks to an automatic Restart Used modules: Main module FX3-CPU1 Expansion module FX3-XTIO Hardware configuration The complete confi guration can be found on the CD included. Used logic functions: NOT, AND Reset Switch On Delay In/Out Summary Page The description of how the used logic blocks work is found in the Flexi Soft Designer Software Users Manual( ). Additional information on / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 19

20 Leak detection at fuel tanks Wiring savings compared with previous solutions In the course of quality control, tanks are checked for leaks though a test machine fitted with two independent testing stations. The tanks are manually inserted into the test control unit. Faulty tanks should be detected and separated before the delivery. Therefore the tanks should be identified by a bar code scanner and afterwards checked for leaks. After a passed test, the tanks are labelled. The unauthorized access during the current testing process should be secured by trap doors, which can only be opened when the machine is stopped. A service mode should be also possible if the doors are open. A manual stop of the machine must also be provided for a controlled stop. Realization Both trap doors are protected by one RE11 safety switch. In this way the testing process can only start if the doors are closed. The testing stations are controlled separately, so that the testing process can start only after one door is closed. Simultaneously, one can insert a new tank into the second testing place. If one door is opened, only the affected testing process stops. In service mode, one E100 enabling switch is located at each testing station. This switch provides a secured service mode of the machine and Application at a glance Industrial sector/branch Applications/type of machine Safety functions Product family in the case of a hazardous situation stop the respective process station. By closing the trap doors afterwards, the testing process starts automatically. Additionally, the machine is fitted with a dual-channel ES21 emergency stop pushbutton. It has to be pressed to stop of the entire machine in the case of a hazardous situation. Therefore the emergency SICK is continuously publishing examples of application solutions on the Internet Safety automation, Hazardous area protection Automotive & vehicle construction Leak detection at fuel tanks Emergency stop function Flexi Soft, ES21, RE13, E100 stop pushbutton is installed right in the middle of the two testing stations. If there is an emergency stop the machine, it starts again by pushing the designated Reset pushbutton. The Flexi Soft safety controller collects the individual safety components and stops one or more parts of the machine depending on the hazardous situation. 20 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

21 Overview Flexi Soft Applications in detail Ordering information and CD Customer use Safe service mode by an enabling switch Parallel operation by dividing the machine into two testing stations Used modules: Main module FX3-CPU0 Expansion modules FX3-XTIO FX3-XTDI Relay expansion module UE10-2FG Hardware configuration The complete confi guration can be found on the CD included. Used logic functions: OR Reset EDM In/Out Summary Page The description of how the used logic blocks work is found in the Flexi Soft Designer Software Users Manual( ). Additional information on / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 21

22 Double cell welding robot High productivity using two loading zones A double cell welding robot handles workpieces at two independent turntables. The access is protected by fences on the right and left side. In one fence there is a service door. The operation is only possible if this door is closed. The entry points by which the worker can access the turntable are always open. Hence, the finished welded pieces of metal can be removed and a new one inserted only if the arm of the robot is in the other cell. The turntable has to be in a safe position as well. Otherwise the robot must stop if someone enters this area. The cell in which the welding arm is working may not be entered. Additional it should be possible to manually stop the robot in an hazardous situation. Realization The access through the service door is secured by a i12s safety switch. If the door is opened, the robot and the turntables stop. The entry points used to exchange material are monitored by M4000 multiple light beam safety devices. Using two IN4000 non-contact safety switches, the position of the centre of the robot is determined. Therefore an interruption of a particual entry point`s M4000 only stops the robot if the arm of the welding robot is in this area. The safe position of the each of the two turntables is detected by a non-contact safety switch IN4000. If the turntable and the robot are in a Application at a glance Industrial sector/branch Applications/type of machine Safety functions Product family safe position, the worker can enter this area to change the part. All safety components are connected to the safety controller Flexi Soft, which safely controls the machine. If there is a complete stop of the robot, the dangerous action of the turntable will also stop. The switch-off signal is send directly from the safety controller Flexi Soft. After a complete stop, the Reset pushbutton has to be pushed to start the machine again. Additionally there SICK is continuously publishing examples of application solutions on the Internet Safety automation, Access protection, Hazardous area protection, Safe position monitoring Metal & steel production Welding robot Emergency stop function, Reset/ Restart, Safe position monitoring Flexi Soft, IN4000, M4000, ES21, i12s is one emergency stop push button ES21 on each access and on each service door which switches off the machine in a hazardous situation. 22 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

23 Overview Flexi Soft Applications in detail Ordering information and CD Customer use Parallel operations are possible Minimized cycle time because of reduced downtime Highest level of safety for the worker through multiple protection Used modules: Main module FX3-CPU0 Expansion modules FX3-XTIO FX3-XTDI Hardware configuration The complete confi guration can be found on the CD included. Used logic functions: AND, OR Reset In/Out Summary Page The description of how the used logic blocks work is found in the Flexi Soft Designer Software Users Manual( ). Additional information on / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 23

24 Stretch film winder Optimal light curtain integration via EFI A high-performance thin film wrapper has to be protected against unauthorized access. The pallets reach the thin film wrapper by conveyer belt, where they are automatically wrapped by a thin stretch film. Finally, they are moved out of the machine and prepared for transport. At both ends of the machine it has to be assured that no worker can come into the winding area. This area is only accessable via two service doors, one of which is used to reload the thin film. If one of these doors is opened, or one of the accesses get entered by a worker, a reset is required. A manual stop of the wrapper by the worker must also be possible. Realization The access of the conveyor belt to the wrapper is protected using an M4000 multiple light beam safety device. Additionally there are muting sensors used to make sure that only loaded pallets can enter the machine. If a person enters, the connected Flexi Soft safety controller detects this different movement and shuts down the machine securely. The access by which the pallets leave the stretch film winder, is protected by a C4000 Palletizer safety light curtain. It detects the pallets profile as it s leaving the thin film wrapper and shuts down the actuator if there is a different pattern. To change the thin film rolls, it is possible to entering a service door Application at a glance Industrial sector/branch Applications/type of machine Safety functions Product family which is protected by an i10 safety locking device. If the front door is opened, the actuators of the film changing machinery are stopped, so that the change of the rolls isn t dangerous. If the back service door is opened, the machine s wrapping motion stops immediately. After entering a reset is required in order to restart the machine. The Reset pushbuttons are on the control cabinet beside the service door. There is also an ES21 emergency stop pushbutton on each side, SICK is continuously publishing examples of application solutions on the Internet Safety automation, Access protection, Hazardous area protection Packaging Stretch fi lm winder Differentiation between men and material (Muting), Emergency stop function, Integration of safe automation into control system on different network (Gateway), Reset/Restart Flexi Soft, M4000, C4000 Palletizer, ES21, i10, WT24 through which a manual shut down of the machine is possible. All safety components are connected to the Flexi Soft safety controller. 24 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

25 Overview Flexi Soft Applications in detail Ordering information and CD Customer use Compact and fl exible control solution Optimal sensor integration via the EFI interface on the main module of the Flexi Soft Remote and continuous diagnose via Profi Net Gateway Used modules: Main module FX3-CPU1 Expansion modules FX3-XTIO Gateway FX0-GPNT Hardware configuration The complete confi guration can be found on the CD included. Used logic functions: AND Reset In/Out Summary Page The description of how the used logic blocks work is found in the Flexi Soft Designer Software Users Manual( ). Additional information on / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 25

26 Pneumatic press Simplified solution with the help of the press function blocks On the pneumatical press one can choose three operating modes using an user mode switch: A two-hand mode, where the two-hand controller must be pushed during the entire cycle, a single-break mode, by which the press starts automatically after one entry into the press and a double-break mode, which starts after two entries into the press. In all three operating modes the worker must be protected from the press using a safety light curtain. For the initial start-up in two-hand mode, a reset is required. If somebody interrupts the press, the press stops and a reset is once more required. Additional there is a service door, which is secured against unauthorized opening during the running of the press. After each switch-over into a new user mode, there must also be a reset required. Application at a glance Industrial sector/branch Applications/type of machine Safety functions Product family SICK is continuously publishing examples of application solutions on the Internet Safety automation, Hazardous area protection Machine tool Press Control modes and operating mode selection, Emergency stop function, Machine controller, Reset/Restart, Safety locking function Flexi Soft, C4000, i10 Lock, ES21 Realization The service door is protected by a safety locking device i10 Lock and can only get opened, if the press is stopped. The frontal access to the press where the work pieces are inserted and removed is protected using a C4000 safety light curtain in all operating modes. The start of the press results from pushing the reset button on the control cabinet for single and double break mode. In two-hand mode the two-hand buttons must be pressed for the entire cycle. The Flexi Soft safety controller takes over the connection and the controlling of all safety devices. In single-break mode, the press is activated by a reset for the first cycle, as it is in the double-break mode. By interrupting the C4000 safety light curtain either once or twice depending on the mode the cycle starts anew. In this case the safety controller detects how often and how long the light curtain is interrupted. In the case of active PSDI time monitoring, the maximum duration of an entire PSDI is limited to 30 sec. The Flexi Soft safety controller stops the press upon unexpected access and a Reset is necessary. An access during the press cycle stops it directly. Additionally, the main valve and the remaining valves are controlled by the Flexi Soft and the movement of the press as well. Finally, an ES21 emergency stop pushbutton is installed outside the press which shuts down and switches it off in case of a hazardous situation. 26 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

27 Overview Flexi Soft Applications in detail Ordering information and CD Customer use Ease of realization using certifi ed press function blocks in the Logic editor Operating mode selection for an individual execution of the press process Used modules: Main module FX3-CPU0 Expansion modules FX3-XTIO Hardware configuration The complete confi guration can be found on the CD included. Used logic functions: OR Reset Two Hand Control(Type IIIA) User Mode Switch Press Single Stroke Break Mode In/Out Summary Page The description of how the used logic blocks work is found in the Flexi Soft Designer Software Users Manual( ). Additional information on / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 27

28 Tyre fabric winder Minimized downtime through a wide range of solutions At a automotive supplier, freshly manufactured textil material is made using flow presses. The material is spooled on two rolls at the end of the machine. This material will be used to produce tires afterwards, where it will be combined with rubber. The rolls rotate slowly and take up the material. The hazard for the workers is that they can become caught up in a roll and trapped. If the rolls are full, they are rotated 90 so that they can be removed by a forklift. Afterwards a new roll can be placed there again. The hazardous rotating movement can hurt a worker and therefore access must be protected. Application at a glance Industrial sector/branch Applications/type of machine Safety functions Product family SICK is continuously publishing examples of application solutions on the Internet Safety automation, Access protection, Hazardous area protection Automotive & vehicle construction Tyre fabric winder Emergency stop function, Reset/Restart Flexi Soft, S3000, ES21 Realization Depending on the progress the material isn t produced at a constant rate. However the rolls rotate at a constant speed. This causes some fabric fibres to fall to the ground. This situation shouln t be result in a shut down. The monitoring of the area is only possible via three safety mats. Due to the light weight of the fabric they won t activate the mat. The weight of a worker in contrast would activate the mat directly if he entered this area. In this case both rolls stop. Afterwards a manual restart is required from outside this area to restart both rolls. The removal area in which the forklift accepts the rolls is protected by two S3000 safety laser scanners which make sure that no worker is inside when the full rolls are removed. After tilting and removing the roll a manual reset is required even if the laser scanners have stopped the machine. Additionally there are four ES21 emergency stop pushbuttons that stop the roll actuators manually. These and all other safety components are connected to the Flexi Soft safety controller. 28 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

29 Overview Flexi Soft Applications in detail Ordering information and CD Customer use Smooth process without interruption Used modules: Main module FX3-CPU1 Expansion modules FX3-XTIO Hardware configuration The complete confi guration can be found on the CD included. Used logic functions: OR Reset In/Out Summary Page The description of how the used logic blocks work is found in the Flexi Soft Designer Software Users Manual( ). Additional information on / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 29

30 Newspaper palletizer Productivity increase thanks to complete protection In a robot cell, two robots arrange and palletize newspaper packages which enter the cell by conveyor belt. The packages are identified by a bar code scanner and either stacked on assigned pallets afterwards or, if they couldn t get detected, sorted out by a robot. The rejected and the palletized packages leave the cell by a conveyor belt. These two accesses have to be secured, so that no worker can enter the cell through these accesses. Additional there are two service doors which have to be secured against unauthorized access while the machine is running. Finally, the space in the cell behind the robot has to be secured so that no worker can enter the working space of the robot above the fences around the cell. Application at a glance Industrial sector/branch Applications/type of machine Safety functions Product family Top Top Top SICK is continuously publishing examples of application solutions on the Internet Safety automation, Access protection, Hazardous area protection Print & paper Newspaper palletizer Differentiation between men and material (Muting), Emergency stop function, Reset/Restart, Safety locking function Flexi Soft, ES21, C4000, S3000, i10 Lock, WT24 Realization Both exits, through which the newspaper palletts or the sorted out packages leave the cell via conveyor belt, are each guarded by a C4000 safety light curtain. Both have two reflex muting sensors which allow newspapers but not workers through. The two safety doors are secured using an i10 Lock safety locking device. The access is only possible if both robots and the conveyor belts are switched off. Once this occurs, an entry button at the door can be pushed to unlock the interlock. Next to each of the doors there is an ES21 emergency stop pushbut- ton which causes the complete robot cell to switch off such that no hazardous situation possible. All safety components are connected to the safety controller Flexi Soft. The S3000 safety laser scanner is connected to this controller and is used to monitor the free space behind the robots in the robot cell. It is excluded that a worker might enter the cell by the conveyor belt, which delivers the newspaper packages from above. If the two robots and the conveyor belts get shut down, a reset is required. The reset buttons are installed next to the ES21 emergency stop pushbuttons. Flexi Flexi 30 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

31 Overview Flexi Soft Applications in detail Ordering information and CD Customer use Compact safety controller, in which the logic is implemented to enhance the productivity of the robot cell Used modules: Main module FX3-CPU0 Expansion module FX3-XTIO Hardware configuration The complete confi guration can be found on the CD included. Used logic functions: OR Reset EDM Routing 1:N Ausschaltverzögerung 2 Sensor Muting In/Out Summary Page The description of how the used logic blocks work is found in the Flexi Soft Designer Software Users Manual( ). Additional information on / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 31

32 Pop-up press Easy configuration via press function blocks A press which produces engine parts should be secured in such a way that the dangerous movement stops if somebody enters the press. The press handles five operating modes. Single stroke, in which a press cycle is initiated by a twohand control and the service mode, in which the press get step by step moved by the two-hand push button. Additional to these two there are a single-break mode and a doublebreak mode, in which the next press cycle is initiated by reaching into the press once or twice. Finally, there is an auto mode in which the press is started by the pushing of a reset button and is stopped only when requested. In all five operating modes the security of the workers has to be assured as the press works with a pressure up to 80 tons. Realization To control the press process the safety controller Flexi Soft is used. A C4000 safety light curtain is connected to this controller which is installed directly on the front of the press where the worker accesses it. It stops the press safely in each operating mode if there is an access to the Pop-up press. In the singleand double-break mode The safety light curtain is additional used to start the press cycle in single- and double-break mode if someone Application at a glance Industrial sector/branch Applications/type of machine Safety functions Product family SICK is continuously publishing examples of application solutions on the Internet Safety automation, Hazardous area protection Machine tool Press Control modes and operating mode selection, Emergency stop function, Machine controller, Reset/Restart Flexi Soft, C4000, ES21 reaches into the press one or two times respectively. Therefore nothing can be inside the protecting area of the press. Additionally, the safety light curtain detects if there is an unexpected access and stops the press. To shut down the press in a hazardous case an ES21 emergency stop pushbutton is installed on the press. This and the two-hand pushbutton, which is used in the operating modes press single stroke, service mode and auto mode to control the press, are also connected to the Flexi Soft. To start the press there is always a reset required. The reset is also required after each operating mode switch or after a shut down of the press. This reset pushbutton is mounted on the control cabinet. 32 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

33 Overview Flexi Soft Applications in detail Ordering information and CD Customer use Inside the safety controller Flexi Soft the logic of all operating modes is implemented using preconfi gured press logic blocks Used modules: Main module FX3-CPU0 Expansion modules FX3-XTIO Hardware configuration The complete confi guration can be found on the CD included. Used logic functions: AND, OR Reset User Mode Switch Universal Press Contact Two Hand Control(Type IIIA) Clock Generator Press Single Stroke Press Set Up Mode Break Mode In/Out Summary Page The description of how the used logic blocks work is found in the Flexi Soft Designer Software Users Manual( ). Additional information on / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 33

34 Metal plate milling machine Two safety fields make continuous milling and material swap possible On a universal milling machine big metal plates are horizontally milled. Because the milling station is freely accessible and moveable, it has to be assured that no worker can be next to the milling head during a milling process. At the same time there has to be the possibility for the workers to check the engaged workpiece without stopping the milling process. Therefore the milling machine has to be separated into two areas. Additional there has to be the possibility to shut down the machine manually in a dangerous situation. The safety components have to be integrated into the machine controller, so that the status of the single components is available all the time. Application at a glance Industrial sector/branch Applications/type of machine Safety functions Product family SICK is continuously publishing examples of application solutions on the Internet Safety automation, Access protection, Hazardous area protection, Safe position monitoring Metal & steel production Milling machine Emergency stop function, Integration of safe automation into control system on different network (Gateway), Safe position monitoring Flexi Soft, S3000, IN4000, ES21 Realization The milling machine is separated into two areas, right and left. If the milling head is inside of one of these areas, the access to the other area has to be possible without shutting down the milling process. Therefore the position of the milling head gets detected by a IN4000 non-contact safety switch. During the position detection it s assured that the access to one of the areas is possible, if the milling head is inside the other one. The complete access area round the machine is monitored by four safety laser scanners S3000, which are installed in the middle of each side right above the bottom. The safety laser scanners, the safety switches and four emergency stop pushbuttons ES21, which are installed at each angle, are connected to the safety controller Flexi Soft. Using the ES21 emergency stop pushbuttons ES21 there is always the possibility to manually initiate a safe shut down of the milling machine. If an emergency stop is activated by one of the components, a reset is required to start the machine again. The restart button is on the control cabinet of the machine. The safety controller Flexi Soft is connected to the machine`s automation controller as well via a PROFIBUS-DP-Gateway, so that all states of the single components can be monitored. 34 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

35 Overview Flexi Soft Applications in detail Ordering information and CD Customer use Increased productivity using two protection fi elds, which are switched by the Flexi Soft Integration of the safety controller via Gateway into the existing function control Used modules: Main module FX3-CPU1 Expansion modules FX3-XTIO FX3-XTDI Gateway FX0-GPRO Hardware configuration The complete confi guration can be found on the CD included. Used logic functions: AND, OR, NOT Reset EDM Routing N:N In/Out Summary Page The description of how the used logic blocks work is found in the Flexi Soft Designer Software Users Manual( ). Additional information on / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 35

36 Test machine for computer chips Integration of the safety controllers diagnostics in the non-safe controller A machine used for testing computer chips s thermal properties should be secured against the hazard of the unauthorized opening of service doors during the testing process and protecting the worker during load and unload of groups of chips. The machine is separated into two areas, the loading area and the process or thermal testing area. In the loading area the chips get inserted or extracted. From there they are transported to the process area, where they get tested for their thermal characteristics for three different temperatures. Both areas are secured by loading or service doors. By opening one of these service doors or by pushing the emergency stop pushbutton a shut down of the machine should follow to protect man and machine. The loading area only switches off the transport mechanism. The state of each door (open/ closed) should be monitored individually. Realization The hazardous area of the transporting units inside the machine is already covered by doors. The machine is separated into the loading and the testing area, which are separated procedurally and secured by four doors. An i12s safety switch is installed at each of the eight doors. By opening one door of the testing area both parts of the machine stop. Application at a glance Industrial sector/branch Applications/type of machine Safety functions Product family However, if a door of the loading area gets opened, only the hazardous transporting movements of the loading area stop. The test continues as switching off this area is time intensive and cannot be reached from the loading area. Additionally two ES21 emergency stop pushbuttons are installed to the machine. These stop the machine manually in a hazardous situation. The connection and control of the safety components is taken over by SICK is continuously publishing examples of application solutions on the Internet Safety automation, Hazardous area protection Electronics Chip testing machine Emergency stop function, Integration of safe automation into control system on different network (Gateway), Safety locking function Flexi Soft, i12s, ES21 the Flexi Soft safety controller. The information of the states of the machine is forwarded via an Ethernet gateway and can get evaluated this way. In this way one can monitor the status of each door and generate a reset signal using the HMI. 36 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

37 Overview Flexi Soft Applications in detail Ordering information and CD Customer use Separate monitoring of each of the safety components via the Ethernet gateway Use of single relays is not necessary 50 Bytes status information via the gateway increases the availability Low downtime by separating the machine into to areas Used modules: Main module FX3-CPU0 Expansion module FX3-XTIO Gateway FX0-GENT Hardware configuration The complete confi guration can be found on the CD included. Used logic functions: AND Reset EDM In/Out Summary Page The description of how the used logic blocks work is found in the Flexi Soft Designer Software Users Manual( ). Additional information on / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 37

38 Robot cell for kitchen door lacquering Non-stop production via safety buffer zone SICK is continuously publishing examples of application solutions on the Internet A robot cell for kitchen door lacquering is separated into three areas, the material loading, the lacquering area and the material unloading. The lacquering area is accessible by two locked service doors. The material loading and the unloading area can be accessed by workers. The rest of the machine is secured by fences. As long as the robot arm is not in the material loading area, this area is freely accessible for the workers. The same is true for the unloading area. The lacquering area cannot be accessed at any time unless the machine is securely shut down. Application at a glance Industrial sector/branch Applications/type of machine Safety functions Product family Safety automation, Access protection, Hazardous area protection, Safe position monitoring Wood / furniture Lacquering robot Emergency stop function, Safe position monitoring Flexi Soft, S3000, M4000, C4000, IN4000, i10 Lock, M4000 Area, ES21 Realization The position monitoring of the robot arm is monitored by three IN4000 non-contact safety switches. Both doors are barred by an i10 Lock safety locking device and can only be unlocked if the robot has stopped. In addition there are four ES21 emergency stop pushbuttons located at the access to the robot cell, one on each service panel to stop the robot in a hazardous case. The material loading is secured by two C4000 safety light curtains, one at the beginning and the end of this area, as well as an M4000 Area multiple light beam safety device, which is installed horizontal at the lower area and is used as an area guarding. If the robot arm is inside this area, the activation of the first light curtain or of the M4000 Area cause to a shut down. If it is in one of the other areas, the light curtain boarding area A secures the area around the robot. The unloading area is secured in similar fashion, except that the multiple light beam safety device is replaced by two S3000 laser scanners as because this area is separated into two separate monitoring zones. The zone nearest to the robot is always enabled, the other one is switched on as needed. All safety A C B components are connected to the Flexi Soft safety controller, which shuts down the robot in a hazardous case. In case of shutdown a reset is required, which occurs from outside the cell. 38 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

39 Overview Flexi Soft Applications in detail Ordering information and CD Customer use Lacquering process doesn t have to be disrupted at any time, hence a higher productivity is assured Workers can access the area where the robot is not actively working without shutting it off, thereby increasing productivity Used modules: Main module FX3-CPU1 Expansion modules FX3-XTIO FX3-XTDI Hardware configuration The complete confi guration can be found on the CD included. Used logic functions: AND, OR, NOT Reset Routing 1:N Interlock Monitoring In/Out Summary Page The description of how the used logic blocks work is found in the Flexi Soft Designer Software Users Manual( ). Additional information on / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 39

40 Beer barrel washing plant Complete machine protection An industrial washing plant for the automatic cleaning of beer barrels should be protected. In this machine, beer barrels between 10 L and 60 L are transported into the machine by a conveyor belt. From there the beer barrels reach an automatic washing plant and pass through the cleaning process. Finally, they are loaded onto pallets. These can be then removed by a forklift. During the complete process it has to be avoided that a worker can enter the machine. While the machine is running, pallets with barrels have to be inserted for cleaning and clean barrels must be removed all without stopping the machine. Additional all safety components have to be monitored and diagnosed individually. Realization The area, at which the barrels get inserted, is protected by two C4000 safety light curtains. These allow new beer barrels to enter the machine without causing shutdown but no person can enter. The cleaning process is protected mechanically such that there is no access for the worker. After the washing process ends, the barrels are discharged from the machine. This area is accessible by two doors, which are each protected by an i10 safety switch. The area, where the pallets are removed from the machine, is protected by a C4000 safety light curtain. Application at a glance Industrial sector/branch Applications/type of machine Safety functions Product family SICK is continuously publishing examples of application solutions on the Internet Safety automation, Access protection Food & beverage Beer barrel washing plant Differentiation between men and material (Muting), Emergency stop function, Integration of safe automation into control system on different network (Gateway), Reset/Restart Flexi Soft, M4000, ES21, i10 This assures that no worker can come inside a running machine, but that the pallets can be removed by forklift. The machine is also fitted with 11 ES21 single-channel, or dual-channel emergency stop pushbuttons, depending on the needed category, so that a manual shut down of the machine is possible in a hazardous situation. All safety components are connected to the Flexi Soft safety controller. A Flexi Soft PROFIBUS-DP Gateway is used to monitor the individual safety components. If one area is shut down a reset is required. For each area reset buttons are installed at the machine housing. 40 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

41 Overview Flexi Soft Applications in detail Ordering information and CD Customer use Compact safety solution for the complete machine Easy implementation of the complex logic Transmission of the status and the situation of all safety devices to the automation controller (PLC) via PROFIBUS-DP Used modules: Main module FX3-CPU1 Expansion modules FX3-XTIO FX3-XTDI Gateway FX0-GPRO Relay expansion modules UE410-4RO Hardware configuration The complete confi guration can be found on the CD included. Used logic functions: AND, OR, NOT Reset Routing 1:N In/Out Summary Page The description of how the used logic blocks work is found in the Flexi Soft Designer Software Users Manual( ). Additional information on / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 41

42 Baking station for meat loaf Worry free implementation of complicated logic A baking station for meat loaf is filled with baking trays by hand. These pans are taken from a conveyor belt placed into the machine one at a time. There they are consecutively baked, tilted to remove the left over grease and then finally offloaded after they pass the cooling station. While the machine is running, the access doors cannot be opened without stopping the machine. The insertion of the baking pans into the entry can only be possible between cycles, even if the conveying system is running. Additionally there should be the possibility to start each cycle manually so that adjustments to the machine can be made. Realization The entry to the baking station is protected by a C4000 safety light curtain, which shuts down the conveyor belt if a pan is inserted midcycle. If a pan is inserted, there is an expected cycle start then no reset is required. If a pan is inserted during the baking process, a reset is required. Additionally, an i110rp rope switch is installed above the entry which stops the machine manually in a hazardous case. The access to the machines individual baking sections is protected by doors at the walkway side. These are monitored by an RE31 non-contact safety switch or an i10 Lock safety locking device. At the side facing the wall, access through a service door is also secured by an i10 Lock. Application at a glance Industrial sector/branch Applications/type of machine Safety functions Product family Access through this door results in a controlled stop with braking. In this way the current cycle is stopped and a safe restart inhibit is assured. At the walkway side, there are two E100 enabling switches, so that the machine can run in service mode even though the doors are opened. The floor above the machine is separated into two areas, the baking and cooling section. The access is protected by a door with an i10 safety door switch each. If one of the doors is opened while the machine is running, the respective area is switched SICK is continuously publishing examples of application solutions on the Internet Safety automation, Access protection, Hazardous area protection Food & beverage Baking station for meat loaf Emergency stop function, Integration of safe automation into control system on different network (Gateway), Safety locking function Flexi Soft, C4000, E100, i10 Lock, RE31, ES21 off. Access to the baking and cooling sections are also secured with doors. An L41 Single Beam Light Switch is mounted in front of these doors, monitors if any doors are opened and finally initiates a switch off command to the respective drive when one is opened. A reset is only possible when all the doors are closed. All components are connected with the Flexi Soft which signals the stop in a hazardous case. 42 PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

43 Overview Flexi Soft Applications in detail Ordering information and CD Customer use The complex logic requires a sophisticated software-based safety controller Complete coverage of the machine, separated into different areas Used modules: Main module FX3-CPU1 Expansion modules FX3-XTDI FX3-XTIO Gateway FX0-GPRO Hardware configuration The complete confi guration can be found on the CD included. Used logic functions: AND, OR, NOT Reset RS Flipflop Two Hand Control(Type IIIA) Switch On Delay Clock Generator In/Out Summary Page The description of how the used logic blocks work is found in the Flexi Soft Designer Software Users Manual( ). Additional information on / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 43

44 Ordering information and CD to the guide Ordering information Main module Number of EFI interfaces Type Order number FX3-CPU ) 2 FX3-CPU ) System plug 1) The memory plug is ordered separately. Description Type Order number Memory Plug FX3-MPL Expansion modules Number of inputs Number of outputs Connector types Type Order number 8 single-channel 4 single-channel Dual level spring clamp set FX3-XTIO Dual level spring clamp set FX3-XTDI Gateways Relay expansion modules Fieldbus Type Order number EtherNet/IP FX0-GENT Modbus TCP FX0-GMOD PROFINET IO FX0-GPNT PROFIBUS-DP FX0-GPRO CANopen FX0-GCAN DeviceNet FX0-GDEV Number of normally closed contacts Number of application diagnostic outputs Connector types Type Order number Pluggable terminals UE410-2RO Dual level spring clamps UE410-2RO Pluggable terminals UE410-4RO Dual level spring clamps UE410-4RO Screw type terminals, fi x UE10-2FG2D Screw type terminals, variable UE10-2FG3D Screw type terminals, fi x UE12-2FG2D Screw type terminals, variable UE12-2FG3D Accessories Description Order number Connection cable 2m Connection cable 10m Adapter from USB to RS-232, UC-232A Screw terminal set (4 pcs.), FX Dual level spring clamp set (4 pcs), FX PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT SICK /

45 Overview Flexi Soft Applications in detail Ordering information and CD For further information and to download the designer free of charge, visit us at / SICK PRODUCTS & APPLICATIONS APPLICATION GUIDE FLEXI SOFT 45

46 / IL/FD Printed in Germany ( ) Subject to change without notice WB USmod int-us34 Worldwide presence with subsidiaries in the following countries: Australia Belgium/Luxembourg Brasil Ceská Republika China Danmark Deutschland España France Great Britain India Israel Italia Japan Nederland Norge Österreich Polska Republic of Korea Republika Slovenija România Russia Schweiz Singapore Suomi Sverige Taiwan Türkiye United Arab Emirates USA/Canada/México Please fi nd detailed addresses and additional representatives and agencies in all major industrial nations at Handed over by: Our Business Segment Expertise Factory automation With its intelligent sensors, safety systems, and automatic identifi cation applications, SICK provides comprehensive solutions for factory automation. Logistics automation Sensors made by SICK form the basis for automating material fl ows and the optimization of sorting and warehousing processes. Process automation Optimized system solutions from SICK ensure effi cient acquisition of environmental and process data in many industrial processes. Non-contact detecting, counting, classifying, and positioning of any type of object Accident protection and personal safety using sensors, as well as safety software and services Automated identification with barcode and RFID reading devices for the purpose of sorting and target control in industrial material flow Detecting volume, position, and contours of objects and surroundings with laser measurement systems Precise measurement of gases, liquids and dust concentrations for continuous monitoring of emissions and the acquisition of process data in production processes Gas flow measurements with maximum accuracy thanks to compact gas meters SICK AG Waldkirch Germany