Robotics Industry can use InduraNET p for wireless communication needs

These days robots have successfully established themselves in a wide range of industrial applications. Whether it's the automotive industry, packaging technology or sheet metal working: industrial robots play an ever increasing role. The increasing level of automation within production processes is promoting the widespread use of robots.

The robotics industry needs a reliable, wireless transmission of standard I/O data to mobile plant or machine sections. The wireless system InduraNET p (Industrial Radio Network) from Pilz is specifically designed for use in an industrial environment.  The remote IP67 module is ideally suited for use on robots (installed on the tool, close to the process). As a result, cable wear and open circuit can be avoided; even dust and water cannot damage the module.

Pilz’s InduraNET p is especially suitable for use in an industrial environment. Key features include high availability thanks to the robust communication technology and a unique antenna system, plus the ability to coexist with other wireless systems. Thanks to its rugged design, the IP67 remote module is suitable for installation close to the process, directly on the sensors. This is important so manufacturers can avoid long cable routes and reduce cable wear.

A connection to all common fieldbus systems means that InduraNET p can be incorporated into existing network architectures. This guarantees a high degree of flexibility when selecting the fieldbus and control system.

Some of InduraNet p’s benefits include:

• Highly available wireless communication in an industrial environment via the InduraNET p protocol and industrial antenna system

• Direct assembly on mobile machine parts – due to a high resistance to dirt and mechanical stress, plus a suitable antenna

• Space-saving application outside the control cabinet – IP67 protection

• Licence-free, uses the free worldwide ISM frequency bands

• Solves the problems of cost-intensive, wearing cable connections

• Connection to all common fieldbus systems

InduraNET p can replace data light beam devices, trailing cables/ cable drag chains, and sliding contacts.

Wind turbine safety increasingly important as industry expands

Wind energy has begun to lead the way in alternative energy solutions.  Manufacturers of wind turbines face challenges such as reducing downtimes and maintenance work.  Some of the demands placed on turbine components include extreme temperature conditions, vibration, oscillation and aggressive offshore air composition.

Keeping wind turbines safely operating is becoming increasingly important as more windmills are built and America begins to use wind as larger source of energy heading into the future.

In the event of a management failure or the failure of individual components, the configurable control system PNOZmulti from Pilz guarantees that the wind turbine is brought to a safe condition for both human and machine.  Some of the safe monitoring functions include: emergency stop pushbutton, master low voltage switch, oil pressure protection and hermetic protection for the medium voltage transformer, and pitch system.  Additional safe monitoring functions include: limit values for true power, vibration, generator speed, rotor speed and line transposition (monitoring of azimuth position) and signals from the fire detection system.

All the safety functions are created directly on the PC with the PNOZmulti Configurator and can be stored on a chip card and downloaded to the base unit.

By differentiating the reaction to various operational circumstances, the PNOZmulti can clearly reduce the load on mechanical wearing parts. A safe condition for both humans and wind turbine can be achieved by reducing the rotor speed and preventing all movements or by switching off hazardous voltages, provided these are not required for the safety function. With PNOZmulti, manufacturers can avoid unnecessary downtimes and thus increase the cost effectiveness of their wind turbines.

PNOZmulti is available in a coated version for use under extreme environmental conditions. This version can be used in extended temperature ranges, permits condensation and is resistant to aggressive air composition.  Also, the configurable control system PNOZmulti can communicate via all relevant fieldbus systems.  With PNOZmulti, applications can achieve up to Performance Level (PL) e of EN ISO 13849-1 and Safety Integrity Level (SIL) CL 3 of IEC 62061. PNOZmulti is certified worldwide.

Another benefit of the PNOZmulti is that the user program is password protected, enabling manipulation protection to be differentiated – with a range of access levels for maintenance staff and installation engineers.

What’s the difference between OSHA and the EU? We Know.

Companies that want to export machinery to the European Union and manufacture machines need to understand the standards and laws that are applicable in both America and the European Union.   Failure to understand the different legal landscapes of the two areas could lead to costly fines and a failure to sell any products.  Manufacturers can get help navigating compliance issues from companies like Pilz.  Pilz specializes in addressing issues like below and can help local companies become global on either side of the ocean.

What are the differences and similarities between OSHA and EU standard? 
An OSHA standard defining the requirements for machine safeguarding is law in the United States of America. A European directive such as the machinery directive is law in each of the 27 member states. A European Union (EU) harmonized standard is not law but enables machine builders and users to gain a presumption of conformance with the law. A standard produced by ANSI through Standard Development Organizations such as PMMI may not enable employers and machine users to show compliance with an OSHA regulation. If this is confusing, it may be time to call Pilz.

Product Liability Laws
Both the EU and the USA have a product liability law which allows individuals to recover damages for injuries sustained due to a defective product. In the case of a worker injured by machinery, the product liability law may apply for the machinery owner. However, the incidence of product liability law cases with regard to machinery accidents is much higher in the USA than in the EU.
In the EU, if a statutory body is involved, it is more likely that the machinery directive will be applied to ascertain whether the machinery was/is in conformance with EU regulations. Was the machine CE marked by the manufacturer? Did the end user import the machine from outside the EU? Has the end user modified it or created an assembly therefore requiring it to be re certified? Is the employer complying with Use of work equipment regulations? 

End-users of machinery must not only meet the obligation to provide a safe place of work. They also need to ensure compliance with local regulations. The challenge lies in ensuring that the workplace is a safe place for employees and that safety is not compromised because of lack of awareness of all applicable legislation, be it local or international. 

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Pilz spreads cheese safely for Edelweiss

These days, cheese production is largely automated. To guarantee the quality of the cheese that is produced in the industrial manufacturing process, plant and machinery must always be state-of-the-art in terms of technology and safety. An individually tailored safety concept as part of a retrofit ensures that processes are safer and more efficient.

This is how Edelweiss in Kempten Germany manufactures its well-known cheese products such as Milkana or Bresso. To optimize processes and product quality in equal measure, Edelweiss completely modernized three mixing plants used to produce cheese spread. They had been in use for more than 15 years, so some parts no longer complied with current requirements in terms of process and safety technology. Although there were no glaring safety defects, some potential danger zones would not have withstood an inspection in accordance with EN ISO 13849.

Edelweiss decided at an early stage to use Pilz as a partner. When it comes to converting, expanding or modernizing existing plants, Pilz not only offers integrated safety and control solutions with the necessary hardware and software, but also supplies a complete package of services and solutions, from risk analysis to CE marking and declarations of conformity. The process always starts with a reliable, transparent risk assessment.

When selecting the relevant technology, Pilz takes particular care to ensure that the chosen hardware performs the task safely and efficiently. In the case of the mixing plants, the cheese manufacturer designed the circuit diagrams and converted the plant itself, using only safety components from Pilz. Safety checks and plant documentation are the final step; these form the basis for issuing the CE declaration of conformity.

With CE certification Pilz assumes legal responsibility for safety, becoming the machine’s manufacturer. With a manageable expenditure of time and money, the three mixing plants are operating once again at the state of the art, in terms of both process and safety technology. “With Pilz we had a partner who is familiar with every aspect, brings the necessary expertise and provides the relevant services. That was a huge advantage,” says Werner Holderried, Head of the Electrical Engineering Department at Edelweiss, summarizing the outcome.

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How to Safely Retrofit a Woodworking Machine

To ensure that plant and machinery are always state of the art, retrofits have become increasingly established in the woodworking industry.

Safety defects that generally arise after many years of use, such as the lack of adequate safeguards, lead to a loss of machine safety. There are several immediate benefits a retrofit can bring: in addition to the updated safety technology, significant investment costs can be saved, because a new investment would cost considerably more. A retrofit will also increase the machine’s availability, as it will again be running smoothly and efficiently.  Pilz provides support in this area with tailor-made retrofit solutions.

For example, double-end tenoners – machines that process two sides of the work piece simultaneously. To increase their precision and availability, the first step is to determine whether the retrofit and increased availability need to be regarded as a significant change.

The width adjustment of these machines is critical: the implementation has to ensure that work piece transportation is safely guaranteed at all times, but that no hazards can arise for operating personnel as the adjustments are made.

The solution can be to use a safety light barrier, PSENopt, or the PSENslock / PSENsgate safety gate systems, both from Pilz. PSENopt provides protection where operator intervention is required as part of each cycle, such as insertion work, or the infeed and outfeed of material. PSENslock / PSENsgate, on the other hand, are integrated safety gate systems and cover functions such as safe monitoring, safe guard locking and control elements, including additional functions such as E-STOP and escape release, all in one unit. All components – whether mechanical or electronic - are integrated within one safety gate system.

Following the retrofit, operators now have the option in “Setup” mode to monitor the width adjustment process in the danger zone, via enable mode. Also, all the individual processing cabins are now secured in such a way that manual setup in “Setup” mode is possible at any time without risk. This gives the operator or tool setter the flexibility he or she needs for the task. “Set up” mode thus incorporates additional measures such as “Enable mode” and “Safely reduced speed”.

Hard real-time communication with RTFL

The RTFL transport layer of SafetyNET p is optimized for the fastest real-time applications. Typically the devices are networked in a linear structure, as with traditional fieldbus systems. All the bus subscribers have equal rights. Data is exchanged in accordance with the publisher/subscriber principle. As a publisher, each device can provide data to the other devices (subscribers) via SafetyNET p. In turn these subscribers can read
the published data from individual subscribers or all subscribers. This way it is possible to exchange data efficiently between all the subscribers. The communication mechanism used by RTFL is a very fast cyclical data transfer in one single Ethernet data frame or multiple data frames per cycle. Communication is initiated by a  special device called the Root Device (RD). The Ethernet frame generated within the Root Device is then  transferred to the other devices (OD – Ordinary Device). The ODs fill the Ethernet frame with data to be  published and extract from the Ethernet frame the data to be read. The devices are addressed via their MAC address. Each RTFL network requires just one Root Device. Each RTFL device has two Ethernet interfaces, which enables the familiar daisy chain wiring often found on fieldbuses.

UDP/IP-based communication with RTFN

The RTFN transport layer of SafetyNET p can be used at process control and manufacturing cell level, where standard Ethernet protocols are in demand and the real-time requirements are lower. RTFN is used to network the RTFL real-time cells and to connect standard Ethernet subscribers, such as visualization devices or service PCs. The RTFN level typically has a tree topology as used in office communication, i. e. with conventional Ethernet. Switches are used to connect the network subscribers in individual point-to-point connections.

RTFN can use two different mechanisms:
The Ethernet MAC frame is used in closed networks. The devices are addressed directly via their MAC address. Then there's the UDP protocol, which is available on most offi ce PCs. In this case the devices are addressed by their IP address. If IP based communication is used, the RTFN frames may also be routed from network to network.