1.
Safety by Design: Soft Safety
(Safe PLC and Integrated Drive Safety)
CMA/Flodyne/Hydradyne
Safety by Design Technical Symposium 2010
April 13th-14th, 2010
Gary Thrall, BRUS/ETC

2.
Safety by Design - Drive for Technology Symposium 2010
Standards
Challenge
New Machine Directive 2006/42/EG PFH
Change of standards PL SIL
- EN 954-1 is going to be replaced Safety Plan
- Probabilistic approach
- Functional Safety Management Software Testing
- Safety requirements for application
programming
Safety concept of all machines to be used Validation & Verification
after Nov 2011 needs to be revised
From the user standpoint
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 2
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

3.
Safety by Design - Drive for Technology Symposium 2010
Standards
How to avoid any hazard ?
The European Machine Directive
(MRL) requires
that the operation, set-up,
maintenance of a machine
does not lead to any hazard
avoidance or minimization of
the hazard
additional measures if the
hazard can‘t be eliminated
information about the
remaining risk
The machine builder has to prove
that everything was done that has
to be done
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 3
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

4.
Safety by Design - Drive for Technology Symposium 2010
Harmonized European Standards
Presumption of conformity
- Fulfilling harmonized standards the machine builder can assume
that the safety aspects of the machine directive are met
State of the Art
- The manufacturer should be sure that the used measures /
technology are state of the art
Type A Basic Standards
Standards ISO 12100 (Principles and Definitions for all Machines)
ISO 14121
EN 954 Type B1
IEC 62061 IEC 60204
ISO 13849 Superior Safety Aspects
Type B
Standards
EN 574 EN 418 EN 61496-1 Type B2
Two-Hand Emergency Stop Safety light curtains Requirements for Safety Devices
Printing Machine tools Presses Packaging
Type C Type C
EN 1010 EN 12417 EN 692 EN 415
EN 12415 EN 693 Specific Requirements
Standards for specific machines
EN 12478
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 4
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

5.
Safety by Design - Drive for Technology Symposium 2010
Standards
Change of Standards
European Machine Directive
98/37/EG 2006/42/EG
January 2012
Machine Builder
EN 954-1
Valid Standard Period 3 years invalid
EN ISO 13849-1 Transition
Valid Standard
November 2006 November 2011
EN 62061
Valid Standard
January 2006
Components
EN 61800-5-2
Valid Standard
November 2007
IEC 61508
Valid Standard
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 5
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

6.
Safety by Design - Drive for Technology Symposium 2010
Standards
Change of Standards
Standards
Safety on Machines
Technology
Source: TÜV Rheinland
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 6
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

7.
Safety by Design - Drive for Technology Symposium 2010
Standards
Change of Standards – Shortcomings of EN 954
Standards intended for complex and programmable electronic Systems
Is not
SafetyFailure Models are not adapted to complex electronic (µC, ASIC’s)
on Machines
Does not consider all aspects of the functional safety
- Failure avoidant safety measures
- Avoidance and control of systematic failures
- Documentation
- Validation
Does not take the probability of dangerous failure into consideration
- categorizes the structural design of safety relevant parts
(hardware) and their reliability and therefore the resistance
against failures and the behavior in case of a failure only
Technology
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 7
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

8.
Safety by Design - Drive for Technology Symposium 2010
Standards
Factory Automation Process Industry
Electric, electronic and
programmable electronic
control systems (E/E/PES)
C-Standards
C-Standards
EN 12417
EN 12417
EN 12415
EN 12415
EN 1010
EN 1010
EN 415
EN 415
…..
….. EN 62061
EN 62061 EN IEC 61511
EN IEC 61511
Safety of Machines
(all technologies)
Two competing standards
EN ISO 13849-1 Does this help building IEC 61508
EN ISO 13849-1 IEC 61508
machines safer?
Machine Builder Vendor
EN 954-1 Invalid after DIN VDE 0801
DIN VDE 0801
EN 954-1
Oct. 30th, 2011
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 8
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

9.
Safety by Design - Drive for Technology Symposium 2010
Standards
Change of Standards
EN ISO 13849-1:2006
+
Deterministic Probabilistic
EN 954-1 IEC 61508
Proven Methods New Concepts
safety functions quantification: reliability
risk graph and testing quality
categories (structure) failures of common
cause
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 9
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

10.
Safety by Design - Drive for Technology Symposium 2010
Standards
What’s necessary to make a machine safe?
Risk
Inherent Process Risk
Risk = Severity x Probability
Change of
Process Design
The higher the contribution to risk reduction
The higher the contribution to risk reduction
Additional Measures the more resistant the safety function must
the more resistant the safety function must
be, that means the small probability of
be, that means the small probability of
dangerous failure is allowed!
dangerous failure is allowed!
Safety
Instrumented
System
EN 62061
residual risk
which is accepted by public IEC 61508
EN 61800-5-2
EN ISO 13849-1:2006
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 10
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

11.
Safety by Design - Drive for Technology Symposium 2010
Standards
Safety Integrity Level Probability of dangerous Performance Level
SIL failure per hour (1/h) PL
IEC 61508 PFHd ISO 13849
- >= 10-5 to 10-4 a
ISO 13849
IEC 62061
1 >= 3 x 10-6 to 10-5 b
1 >= 10-6 to 3 x 10-6 c
2 >= 10-7 to 10-6 d
3 >= 10-8 to 10-7 e
4 < 10-8 -
electrical, electronic and Safety-related Parts of Control System
programmable electronic control of all Technologies
Systems
Simplified Estimation (worst case)
calculation formula regarding to:
for subsystem architectures HW Structure (Category like EN 954)
Diagnostic Coverage (DC)
Reliability MTTFd
Failure of Common Cause (CC)
Safety Software Requirements
Measures for control and avoidance of systematic failures
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 11
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

12.
Safety by Design - Drive for Technology Symposium 2010
Standards
Simplified V-model of software safety life-cycle (Annex J)
General requirement: readable, understandable, testable, maintainable
Safety Safety related Validation Validated
Functions Software Validation Software
Specification specification
System Integration
design Testing
Verification Software
Specification:
- erroneous interpretation Module Module
- avoiding gaps Design Testing
- precisely defining conditions
- all the possible cases are handled
- consistency tests Verification Coding:
Coding
- the different parameterizing cases Programming Guide Lines
- the reaction following a failure
Verification
Output
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 12
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

13.
Safety by Design - Drive for Technology Symposium 2010
Standards
Software Safety Requirements (Extract)
PL c to e
- Software design
– State diagram or program flow chart
Safety – Modularrelated structured programming
Safety and Validation
Validated
Functions Software Validation
– Function blocks of limited size of coding
specification
Software
Specification
– Code execution inside FB should have one entry and one exit
point
System Integration
– Architecture: input –> processing ->Testing
design output
– Assignment of a safety output at only one program location
– Techniques Modulefor detection of external failure and for defensive
Module
programming Design Testing
– Safety related and non-safety related application Software shall
be coded in different function blocks with well-defined data links
Coding
– No logical combination of non-safety and safety related data that
lead to downgrading of the integrity level (e.g. no OR allowed)
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 13
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

14.
Safety by Design - Drive for Technology Symposium 2010
Standards
Harmonization of International Standards
North America Europe
ISO 12100 / ISO 14121
OSHA Machine Directive
ISO 13849-1
ANSI/PMMI B155.1 EN ISO 13849-1
IEC 61508
ANSI B65.1 EN 62061
NFPA 79:2007 EN 60204
etc. IEC 60204
IEC 62061
IEC 61800-5-2
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 14
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

15.
Safety by Design - Drive for Technology Symposium 2010
Standards
Harmonization of International Standards
NFPA 79: 2007 (examples from Annex A)
- A9.2 Information on the safety-related aspects of control
functions is under consideration within IEC 62061 and ISO
13849 (revision)
- A9.4.1 IEC 62061, ISO 13849-1, ISO 13849-2 and ANSI
B11-TR4 give guidance on design according to the
determined risk reduction in the risk assessment.
- A9.4.3.2 IEC 62061, ISO 13849-1, ISO 13849-2 provide
requirements for the design of control systems incorporating
the use of software- and firmware-based controllers to
performing safety-related functions. IEC 61508 provides
requirements for the design of software- and firmware-based
safety controllers. IEC 61800-5-2 and IEC 61508 give
guidance to the drive manufacturer on the design of drives
intended to provide safety functions.
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 15
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

16.
Safety by Design - Drive for Technology Symposium 2010
Standards
Harmonization of International Standards
NFPA 79:2007
- 9.2.5.4.1.4* Where a Category 0 or Category 1 stop is used for
the emergency stop function, it shall have a circuitry design
(including sensors, logic, and actuators) according to the
relevant risk as required by Section 4.1 and 9.4.1. Final
removal of power to the machine actuators shall be ensured
and shall be by means of electromechanical components.
Where relays are used to accomplish a Category 0 emergency
stop function, they shall be non retentive relays.
Exception: Drives, or solid state output devices, designed
for safety-related functions shall be allowed to be the final
switching element, when designed according to relevant
safety standards
(Annex A refers to the European Standards)
A.9.2.5.4.1.4 IEC 61508 and IEC 61800-2 - Designed for Safety
Without this design confirmation the system will still require the
electromechanical means of final disconnect.
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 16
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

17.
Safety by Design - Drive for Technology Symposium 2010
Standards
Harmonization of International Standards
ANSI/PMMI B155.1
- This version of the standard has
been harmonized with
international (ISO) and European
(EN) standards by the introduction
of hazard identification and risk
assessment as the principal
method for analyzing hazards to
personnel and achieving a level of
acceptable risk. This version of the 1)
standard is a major revision that
integrates the requirements of
ISO 12100 parts 1 and 2, and ISO
14121, as well as U.S. standards.
Suppliers meeting the requirements
of ANSI/PMMI B155.1:2006 may
simultaneously meet the
requirements of these three ISO 1) Risk Scoring like ISO 13849
may be used.
standards.
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 17
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

18.
Safety by Design - Drive for Technology Symposium 2010
Standards
Harmonization of International Standards
ANSI/PMMI B155.1
- 7.2.8 Programmable electronic systems (PES) used in safety
functions
– 7.2.8.1 General
PES may include a programmable logic controller (PLC),
servo motion controller, computer numerical control (CNC),
personal computer, human-machinery interface (HMI) or
programmable limit switch (PLS). American National
Standard ANSI/PMMI B155.1-2006 Page 29. A PES can
be applied to safety functions when the design and use of
the system meets the requirement(s) of the risk
assessment. The design measures of the PES shall be
chosen so the safety related performance provides
adequate risk reduction per ISO 13849-1, and meets the
appropriate safety integrity level (SIL) per IEC 62061. The
PES shall be installed and validated to ensure that the
specified performance for each safety function has been
achieved. See also SIL in IEC 61508-5, IEC TR 61508-0..
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 18
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

19.
Safety by Design - Drive for Technology Symposium 2010
Standards
Harmonization of International Standards
ANSI/RIA/ISO 10218-1-2007 (Robots for Industrial Environment –
Safety Requirements) Part 1 – Robots
- In 2007, according to Roberta Nelson Shea, U.S. robot users
may soon gain greater access to these and other emerging
technologies. That will come with the approval by ANSI - the
American National Standards Institute - of ISO 10218 Part 1,
an international robot safety standard that was published last
June by the International Organization for Standardization
(ISO)...
- Approved by ANSI 8/17/2007 as ANSI, RIA, and ISO standard
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 19
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

20.
Safety by Design - Drive for Technology Symposium 2010
Standards
Benefits of Harmonization of International Standards
End User
- Same standards for machines sourced worldwide coming
into their plant
- Multi-nationals can use same standards for plants at
locations worldwide
Machine builder
- Same standards for users worldwide – reducing need for
design variants
Equipment and Component suppliers
- Same standards for users worldwide – reducing need for
certification to different (and in the past sometimes
conflicting) standards
All
- Same methodologies defined by IEC-61508 to be used in
all industries and applications
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 20
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

21.
Safety by Design - Drive for Technology Symposium 2010
Standards
Listed Testing Laboratories by the Occupational Safety and Health
Administration (OSHA)
Standards approvable by NRTL
NRTLs listed by OSHA
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 21
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

22.
Safety by Design - Drive for Technology Symposium 2010
Integrated Safety on Levels of IndraMotion
Challenge
New Machine Directive 2006/42/EG PFH
Change of standards PL SIL
- EN 954-1 is going to be replaced Safety Plan
- Probabilistic approach
- Functional Safety Management Software Testing
- Safety requirements for application
programming
Safety concept of all machines to be used Validation & Verification
after Nov 2009 needs to be revised
From the user standpoint
Chance
Make it right from the beginning. Upgrade it to state of the art
Modern safety technology offer advantages for machine builders
and end users
International harmonized standards make global business easier
since ANSI refers on newer IEC standards
Using certified components makes life easier
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 22
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

23.
Safety by Design - Drive for Technology Symposium 2010
Integrated Safety on Levels of IndraMotion
Safety on Board offers a simple and safe implementation of functional
safety in accordance with safety standards and keeps the availability of
the machine at the highest level
SafeLogic increases the flexibility of the safety application
SafeMotion raises the productivity of the machine
Safe Process
Flow Control
Control
Safe Processing
Transmission
Safe Data
Network
Safe Communication
Safe Movement
Drive
Avoidance of unintended movement
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 23
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

24.
Safety by Design - Drive for Technology Symposium 2010
Integrated Safety on Levels of IndraMotion
Drive based Safety Functions
Safely monitored Deceleration
Safe Torque Off
Safe Operational Stop
Safe Stop 1
Safe Stop 2
Safely limited Speed
Safe Maximum Speed
Safely limited Increment
Safe Direction
Safely limited Position
Safe Position Switches
Safe Homing Procedure
Safe Door Locking
Safe I/O interface for Safety-PLC
Safe Braking and Holding System
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 24
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

25.
Safety by Design - Drive for Technology Symposium 2010
Integrated Safety on Levels of IndraMotion
Safe Braking and Holding System – A New Milestone!
Fall protection on axes with gravity loads
World’s only onboard solution which
complies with EN 954-1 Category 3
Two independent brakes separately
controlled and monitored by redundant,
diverse channels in the drive
Escalation strategy to protect the
mechanical subsystems
Applications
Presses
Reel Stands
Loading gantries
Vertical guard doors
…
Electric Drives and Controls 2008-03-08;
2008-03-06; BRC/PRM3; J. Ost 25
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

26.
Safety by Design - Drive for Technology Symposium 2010
Integrated Safety on Levels of IndraMotion
Safety On Board with IndraDrive
Dynamization
3 principles are realized to detect latent failures
Dual channel data operation with diversity
Cross data comparison of safety related functions
Dynamization of static modes
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 26
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

27.
Safety by Design - Drive for Technology Symposium 2010
Integrated Safety on Levels of IndraMotion
IndraDrive Certificates – For global Business!
SIBE Certificate accepted by TÜV Rheinland
- EN 954-1, ISO13849-1:1999
NRTL listing by TÜV Rheinland North America
- NFPA 79, UL 508C, CAN/CSA C22.2,
ISO 13849-1:1999
IEC 61508 certification by TÜV Rheinland and TÜV
Rheinland of North America in work
- IEC 61508, IEC 61800-5-2, ISO 13849-1: 2006
- with MPx06Vxx in 4Q/2008
- S2, L2 control units
IndraDrive Mi and IndraDrive Cs with
safety technology
- Expected availability: 2010
Electric Drives and Controls 2007-11-05; BRC/PRM3; J. Kobs
2008-03-06; BRC/PRM1; G.Ost 27
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

28.
Safety by Design - Drive for Technology Symposium 2010
Integrated Safety on Levels of IndraMotion
IndraDrive with Safety Functions – A Convincing Technology!
Safety Technology made by the experts having more
than 8 years field experience
Scalable Safety Functions minimize the potential of
tampering and therefore reduce the hazard for injury
caused by bypassing the safety measures
Increased productivity by reducing downtime
Online Testing (Failure Detection) during runtime
Cost savings by reduction of external components and
wiring
Minimal Movement in case by detecting failures within
2ms
High reliability due to a encapsulated, certified solution
Independent, whether wired, or with or without a safety
PLC
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 28
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

29.
Safety by Design - Drive for Technology Symposium 2010
Integrated Safety on Levels of IndraMotion
Example Printing
Safety Functions
“ASP“ used for E-Stop and
“Stop/Locking“. (Machine stop
synchronized by the virtual master
axis)
Safe Operational Stop when guards
are open
Safely limited speed in combination
with safe direction for jogging
forward and backward
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 29
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

30.
Safety by Design - Drive for Technology Symposium 2010
Integrated Safety on Levels of IndraMotion
Example Printing
“ASP“ used for E-Stop and “Stop/Locking“.
(Machine stop synchronized by the virtual master
axis)
Safe operational stop at printing
cylinder for sleeve change
Safely limited speed for cylinder
washing or jogging with open
guards
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 30
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

31.
Safety by Design - Drive for Technology Symposium 2010
Integrated Safety on Levels of IndraMotion
Example printing
Tool plate could come off
Safe Mode:
if centrifugal force
- Safe Drive Interlock (ASP) becomes higher than
- Safe Operational Stop (SBH) magnetic force
- Safely limited Speed (SBB)
- Safely limited Speed with Safe Direction
Normal Operation:
- Safe Maximum Speed
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 31
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

32.
Safety by Design - Drive for Technology Symposium 2010
Modern Safety Technology on Machines
Flexibility
Safety-Field bus
connection to periphery
E30 E1
E1
E30
E1
E1 Safety-Installation bus
also parameterizable,
modular Safety Modules
Complexity
A B C D
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 32
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

33.
Safety by Design - Drive for Technology Symposium 2010
Modern Safety Technology on Machines
Directly Hooked up to the Drive (A)
No-Safety PLC
Door interlock can be controlled by the drive
Connection to periphery
Both channels discrete wired
- Requires open-contactor and
antivalent signals (may require relays
with ESPE, E-Stop, Enabling)
One channel via the command variable
- Requires open-contactor (may require
relays with ESPE)
Diagnosis
By reading drive parameter
In case of direct wiring of both channels
extra wiring to the controller necessary for
detailed information
A
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 33
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

34.
Safety by Design - Drive for Technology Symposium 2010
Modern Safety Technology on Machines
Directly Hooked up to the Drive (A)
Discrete inputs allow multiple safety functions
ASP
Operation Mode (normally series
connection of all safety devices which put
the drive in SBH
Enabling
SB1 / SB2 switch
When to use?
Small machine with limited safety
functions
Just wiring and parameterization of the
drive
A
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 34
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

35.
Safety by Design - Drive for Technology Symposium 2010
Modern Safety Technology on Machines
Safety Modules (B)
No-Safety PLC
Connection to periphery
via Safety Modules
- One channel direct wired
- One channel via the command
E1
variable
E30 (Parameterizeable) Safety Modules can
offer the possibility to build groups
(simple “AND” “OR”) at reduced wiring
efforts
E1
Diagnosis
By reading drive parameter
also parameterizable, Safety Modules offer diagnosis
modular Safety Modules
capabilities which might be linked to the
standard control via field bus
B
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 35
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

36.
Safety by Design - Drive for Technology Symposium 2010
Modern Safety Technology on Machines
Safety Modules (B)
Discrete inputs allow multiple safety
functions
ASP
Operation Mode (normally series
connection of all safety devices
E1
which put the drive in SBH
E30
Enabling
SB1 / SB2 switch
E1
When to use?
Small machine with less
also parameterizable, complex safety functions
modular Safety Modules
Just wiring and parameterization of
the drive
B
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 36
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

37.
Safety by Design - Drive for Technology Symposium 2010
Modern Safety Technology on Machines
Safety Modules (B) - Example
Euchner SK
qTür_Arbeitsraum_entreiegln
PLC Drive Drive
qAx_SafOpModeSwitch (E2)
qNormal_operation
Diagnosis & Diagnosis &
qDynam (EA30)
Dynamization Dynamization-
Master Slave
EA10n
EA20n
EA10n
EA20n
EA30
EA30
E2n
E2n
PNOZ Load door
K11
K12
Euchner TZ
K11 K12
K21 K22
PNOZ Work space door
K30
K21
K22
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 37
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

38.
Safety by Design - Drive for Technology Symposium 2010
Modern Safety Technology on Machines
Safety Modules with limited logic processing functionality (C)
Safety Controller with limited capabilities
(Parameterizable) Safety Controller can
offer some logic processing capabilities
Limited number of I/Os
Connection to periphery E30 E1
via Safety Controller
- One channel direct wired
- One channel via the command E1
variable
Installation bus reduces wiring efforts
Diagnosis Safety-Installation bus
By reading drive parameter
Safety Modules offer diagnosis
capabilities which might be linked to the
C
standard control via field bus
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 38
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

39.
Safety by Design - Drive for Technology Symposium 2010
Modern Safety Technology on Machines
Safety Modules with limited logic processing functionality (C)
Discrete inputs allow multiple safety
functions
ASP
Operation Mode (normally series
connection of all safety devices
E30 E1
which put the drive in SBH)
Enabling
SB1 / SB2 switch
E1
When to use?
Machines with mid-range Safety-Installation bus
complexity
Wiring and parameterization of the
drive and safety processing unit
C
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 39
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

40.
Safety by Design - Drive for Technology Symposium 2010
Modern Safety Technology on Machines
Safety Modules with some logic processing functionality (C)
Euchner TP3 PLC IndraDrive IndraDrive IndraDrive
iAx_SafCtrlOutputState (A10)
qAx_SafOpModeSwitch (E2)
qDynamization (EA30)
Diagnosis & Diagnosis & Diagnosis &
Dynamization Dynamization Dynamization
Master Slave Slave
qDoor_Lock
EA20n
EA20n
EA20n
EA10
EA30
EA10
EA30
EA30
EA10
E2n
E2n
E2n
+24V
+24V
PNOZ i0 i1 i2 L1 o4
Multi
i5 i6 i3 o0 i4
-A1
+24V
Example for a drive group
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 40
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

41.
Safety by Design - Drive for Technology Symposium 2010
Modern Safety Technology on Machines
Simple wiring recommendations for drive groups
Special connector kit for
9 pin ribbon cable
going over from standard wiring
to 9 pin ribbon cable
Hardwiring from safety relays to
9 pin ribbon cable
Ease of use by
crimp connectors
Ease of diagnostics by
24Volt signals
Standard wiring
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 41
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

42.
Safety by Design - Drive for Technology Symposium 2010
Modern Safety Technology on Machines
Safety Modules with some logic processing functionality (C)
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 42
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

43.
Safety by Design - Drive for Technology Symposium 2010
Modern Safety Technology on Machines
EStop Door 1 Door 2 Door n
Sicherer Sicherer Sicherer Sicherer
AS-i Slave AS-i Slave AS-i Slave AS-i Slave
IndraDrive IndraDrive IndraDrive IndraDrive
EA30
EA30
EA30
EA30
E1n
E2n
E3n
E1n
E2n
E3n
E1n
E2n
E3n
E1n
E2n
E3n
AS-i
EStop Safety
Monitor
AS-i
Protection Safety
Area I/O Monitor
Enable AS-i
Safety
Monitor
iEnable
Consent
iProtection_Area_not_IO PLC
iEStop
qDynamization
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 43
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

44.
Safety by Design - Drive for Technology Symposium 2010
Modern Safety Technology on Machines
Programmable Safety Control (D)
Programmable Safety Controller
Flexible (IEC61131-1) programming
- FBs Safety-Field bus
- OEM libraries
“unlimited” number of I/Os
Connection to periphery
Safety-I/O
- Built-in diagnosis
Safety Field bus
- Standard, Safety-I/O and Drive on one
field bus
- reduces wiring efforts
Diagnosis
D
Implicit diagnosis of the Safety-I/Os
within the standard diagnosis
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 44
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

45.
Safety by Design - Drive for Technology Symposium 2010
Modern Safety Technology on Machines
Programmable Safety Control (D)
Safety-Field bus allows unlimited
safety functions
Boolean Control and Status Bits Safety-Field bus
Feedback and Command values
Drive as I/O unit
When to use?
Machines with higher complexity
Common powerful diagnosis
Common engineering
Programming of safety functions
(instead of wiring)
D
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 45
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

46.
Safety by Design - Drive for Technology Symposium 2010
Modern Safety Technology on Machines
Why a Safety-PLC is not enough!
However
- Many machines can be done without a Safety-PLC
- Bosch Rexroth can offer real safe motion which is the key to
increase the productivity and safety, since the operator can
do his job, he does not get hindered and motivated to tamper
the safety measures.
- There are alternative concepts possible even with a
competitors PLC
Our competitors may offer a Safety-PLC
- But they can’t offer safe drives which provide more than a
safe stop or standstill
- There is no alternative available
Bosch Rexroth is on it’s way to offer an integrated Safety-
Control for all system solutions and all platforms
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 46
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

47.
Safety by Design - Drive for Technology Symposium 2010
Integrated Safety on Levels of IndraMotion
Why Safe Logic Processing?
Complex machines with
Multiple access areas
Multiple safety zones
Multiple operation panels
Fine-scaled safety functions
Escalated reaction rather than
always shutting down
Safety Levels regarding the
authorization Levels of
Machine operator
Maintenance people
Cleaners
Service
Maintenance
Personnel Versatility
Cleaners
Modular machine design
Machine
Service Operators Tailored to customer preferences
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 47
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

48.
Safety by Design - Drive for Technology Symposium 2010
Integrated Safety on Levels of IndraMotion
Traditional Solutions offer Potential for Improvements
Failure detection
Minimizing the residual risk
Standard Safety Wiring
Control Control
Cost cutting of hardware and
soft costs
Different
Engineering Tools Interfaces
Additional Safety
Reduction of interfaces and
Data Exchange IO minimizing the data exchange
and programming effort
Standard
Discrete Signals
IO Auto Set-up
Availability
Limit safety
Functions Integration of the drive based
safety functions in the overall
engineering (diagnosis)
Validation
+
+ Effort reduction by using
certified functions
SafeMotion
SafeMotion -
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 48
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

49.
Safety by Design - Drive for Technology Symposium 2010
Integrated Safety on Levels of IndraMotion
Integrated Solutions – Standard and Safety merge together
One certified automation system
Standard
MC
Safety
SI Standard + Safety
Control Control
SafeLogic One certified engineering system
Standard + Safety
One certified communication system
Safety
IO Standard + Safety
Standard Certified FBs to represent the drive
IO Auto Set-up
based safety functions in the PLC
Certified FBs for analysis of the
safety periphery
SI
Data exchange between motion and
+
+ safety on system level
SafeMotion
SafeMotion -
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 49
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

50.
Safety by Design - Drive for Technology Symposium 2010
Integrated Safety on Levels of IndraMotion
Flexible connection of all components via one single network
Standard Safety Control
Control
IO
Safety I/O
Drives
Safety
IndraWorks SafeLogic
SafeLogic Safety Drive
Engineering Control
IO
IndraControl L IndraControl V
Drives
One-cable Safety-Network
IndraDrive SERCOS safety
Inline Inline
Consistent Engineering
IndraDyn IndraDyn with IndraWorks
Integration of 3rd party components
PROFIsafe
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 50
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

51.
Safety by Design - Drive for Technology Symposium 2010
Integrated Safety on Levels of IndraMotion
SafeLogic – Just added when needed!
Safety Function Module converts standard
controller into a safety controller
Safety
Optional extendible (can be upgraded
later)
No interference (constant cycle times,
standard program and safety program
Logic Motion
have no influence on each other)
Seamless engineering and diagnostics in
the standard control context
IEC 61131-3
IEC61131-3
No need for synchronization interfaces
between the safety controller and the
standard controller
Hardware
Applications program
Electric Drives and Controls 2008-03-06; BRC/PRM3; J. Ost 51
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.