1. Safety Monitoring system for a
manufacturing workstation using Web
Service Technologies
Date: March, 2012 Conference: The 13th Annual
Linked to: eSONIA (ARTEMIS Project) Conference of the IEEE International
Conference on Industrial Technology
Title of the paper: Safety Monitoring
system for a manufacturing workstation
using Web Service Technologies
Contact information Authors: Prasad Karipireddy, Axel
Vidales, Jani Jokinen, Jose L.Martinez
Tampere University of Technology,
Lastra
FAST Laboratory,
P.O. Box 600,
FIN-33101 Tampere,
Finland
If you would like to receive a reprint of
Email: fast@tut.fi the original paper, please contact us
www.tut.fi/fast

2. 2
Safety Monitoring system for a
manufacturing workstation using Web
Service Technologies
Authors: Prasad Karipireddy, Axel Vidales, Jani
Jokinen, Jose L.Martinez Lastra
Tampere University of Technology
Factory Automations Systems and Technologies Lab.
www.tut.fi/fast
ICIT 2012, Athens, Greece
19-21.3.2012

3. 3
Outline
1. Introduction
2. Objective
3. Implementation
4. Results
5. Conclusions and future work

4. 4
Introduction (1/2)
1. Safety in manufacturing industry
2. Safety device development
3. Increased complexity & demands (manufacturing & safety
devices)
Requirement: Better safety monitoring solutions

5. 5
Introduction (2/2)
Main problems for monitoring safety:
1. Insufficient safety data
2. Lack of interoperability

6. 6
Objectives
1. Real time monitoring of safety data
2. Increase safety information resolution
3. Increase safety information availability, provide openness
4. Isolate safety network from standard network
5. Implement the new system for real industrial platform

7. 7
eSONIA - project
• eSONIA - Embedded Service-Oriented Monitoring, Diagnostics
and Control: Towards the Asset-Aware and Self-Recovery
Factory.
• ARTEMIS CALL 2009 Project, SP4: Efficient manufacturing and
logistics
• The eSONIA consortium consists of 15 partners. The project
partners are from Finland, Italy, Spain and the Czech Republic
• Pilots in Automotive, Construction and Pulp&Paper
http://www.esonia.eu/

8. 8
Validation environment

9. 9
Robot workstation (old configuration)
Standard area
• Robot
• Conveyor system
• Feeders
Safety area
• Safety interlock switches x 8
• All in one series
• Emergency stop buttons x 4
• All in one series
• Safety relays

10. 10
Proposed architecture
Third Party
ERP Remote SCADA
Applications
WS WS WS
Enterprise
Level
Internet
MES DCS
WS WS
Local Site Internet Protocol
Level
WS WS
Local SCADA WMS
WS
Web Service Gateway
Safety fieldbus
Safety fieldbus
Safety Safety fieldbus Safety fieldbus Safety fieldbus Safety fieldbus
Level
Safety PLC Safety PLC Safety PLC Safety PLC

11. 11
Safety implementation
Safety area
• Safety interlock and E-stop buttons was individually wired
• Safety PLC
• Safety fieldbus
Integration
• Ethernet gateway
• Web service supported controller
Specifications of devices used in workstation:
Device name Model name No
Safety PLC Pluto B46 (Jokab) 1
Safety switches (2-channel, NC ) Omron 1AFS 8
E-stop buttons (2-channel, NC ) Schneider 4
Starter and reset buttons Schneider 2
Ethernet gateway GATE-E2 (Jokab) 1
Safety fieldbus Pluto bus 1
Web Services supported PLC S1000 (Inico) 1
Standard fieldbus Standard ethernet 1

12. 12
Safety area of the workstation
Remote monitoring 3rd party
system applications
WS
Enterprise WS
Level
Internet
Remote
MES etc..
smart RTU
WS WS
Local Site Internet Protocol
Level
WS
Local Monitoring
system
Workstation WS
Ethernet gateway
Pluto bus (CAN)
WS WS WS
Std Conveyor Robot Feeder
Safety Pluto PLC
area control interface control area
Sensors Robot Sensors Safety Emergency Starter
and control and interlock stop and Reset
actuators cabinet actuators switches buttons buttons

13. 13
HMI

14. 14
Safety Event Monitoring in third party
monitoring application

15. 15
Conclusions and future work
1. Detailed safety information
2. Safety levels improved
3. Interoperable solution
4. Safety information can be monitored by operator through
embedded HMIs
5. Safety information are published as events and can be
integrated to any 3rd party monitoring application supporting
WS-Eventing
6. Future work is to develop new applications for utilising both
safety and non-safety information