This presentation discusses integrating safety light curtain sensors with an industrial robot (KR30) to prevent human-robot collisions. It involves researching safety sensors, analyzing light curtain sensors and a Beckhoff I/O module, and connecting the sensors to the robot. The light curtains would detect human presence and halt the robot to ensure safety during operation. Block diagrams, specifications, cost analysis, applications and future enhancements are also covered.

1. TITLE
PROJECT PRESENTATION
ON
“INTEGRATION OF SAFETY LIGHT CURTAIN
SENSORS WITH KR30”

2. CONTENTS
TIMELINE
PROJECT SUMMARY
PROJECT PARTS
BLOCK DIAGRAM
COMMUNICATION PROTOCOL
BECKOFF MODULE
SPECIFICATION
TIME AND COST ANALYSIS
PROJECT APPLICATION
FUTURE ENHANCEMENT
CONCLUSION

3. TIMELINE
PHASE
1
PHASE
2
PHASE
3
PHASE
4
RESEARCHED
INDUSTRIAL
ROBOTS AND
SAFETY
MEASURES
USED BY
INDUSTRIES.
ANALYSIS AND
COMPARISION
OF DIFFERENT
SAFETY
SENSORS.
HARDWARE
ANALYSIS OF
CURTAIN
SENSORS AND
BECKOFF
MODULE WITH
DIFFERENT
TESTS.
CONNECTION
OF SENSORS
WITH KR30
THROUGH
HARD WIRES.

4. SUMMARY
PROBLEM THAT WE ARE FACING:
Industrial Robots produce powerful and very rapid movements in a large operational space and when accidently
human comes in contact with the robot during its process, it can harm human.
SOLUTION THAT CAN BE IMPLEMENTED
• To ensure safety in industrial area, safety light curtain sensors can be used.
For example:In welding robots, interfacing of safety sensor system can be used to resist the human intervention in
operational workspace.
• Safety light curtain sensor is an effective and optimized device that can reduce numerous accidents.

5. PROJECT
PARTS
1) LIGHT CURTAIN SENSORS
2) CABLE SETS AND CONNECTORS
3) BECKHOFF I/O MODULE
4) KUKA CONTROL PANEL C4

6. BLOCK
DIAGRAM
Input sensing device
IPC
PROGRAMMING
DEVICE
OUTPUT LOAD
DEVICE(KR30)

7. MODULE
• Beckhoff module implements open automation system which covers Industrial PCs, I/O
and fieldbus components, drive technology and automation software.
• Products are integrated to control system using Beckhoff automation technology.
• It supports interprocess communication(IPC) that allow a programmer to coordinate
activities among different program that can run concurrently in a control system.
• It provide wide choice of I/O components means that the bus system best suited to the
particular application can be chosen.

8. COMMUNICATION
PROTOCOL
• EtherCAT is a highly flexible Ethernet network protocol that is developing at a rapid rate.
• A fieldbus system called Fast Lightbus to correct the low bandwidth utilization problem
present in other Ethernet protocols. This protocol led to EtherCAT which Beckhoff released in
2003.
• EtherCAT uses the standard IEEE 802.3 physical layer. No special hardware is required to
implement an EtherCAT network.
• The data representation in ethercat protocol is done by address bits, message and error
detection bit.
• Main advantage of ethercat protocol is:
1. Speed
2. Flexible topology
3. Synchronization

9. FLOWCHART
IS WORK
DONE
START
HUMAN
PRESENCE
IF HUMAN
GOES OUT
RESUME THE
PROCESS
HALT THE PROCESS
PROGRAM RUN
STOP THE PROGRAM
END
NO
YES
NO
YES
NO
YES

10. SPECIFICATIONS
1. LIGHT CURTAIN SENSORS
Features data
RESOLUTION 25mm
SENSING HEIGHT 180mm
OPERATING VOLTAGE 24+/-20%VDC
CURRENT CONSUMPTION 60mA
RESPONSE TIME 10ms
INDICATOR YELLOW(POWER)
GREEN(CLEAR CONDITION)
RED(BLOCK CONDITION)

11. SPECIFICATIONS
2. BECKHOFF MODULE
FEATURES DATA
DATA TRANSFER MEDIUM EtherCAT/Ethernet
NO. OF EtherCAT TERMINALS Up to 65,534
COMMUNICATION PROTOCOL EtherCAT
DATA TRANSFER RATE 100 Mbit/sec
POWER SUPPLY 24V DC
CURRENT supply E-bus 2000 mA

12. TIMEAND
COST
TASK TIME ITEMS COST
RESEARCH
WORK
2 MONTHS MECHANICAL
PARTS
NULL
REPORT
WRITING/
PRESENTATION/
ACCESSING
ORDERS
1 MONTH DOCUMENTATION
AND OTHER
EXPENSES
₹ 500/-
SYSTEM
DESIGNING
1 MONTH PROTOTYPE
DEVELOPMENT
NULL
HARDWARE
PROTOTYPE
2 MONTH HARDWARE
CIRCUITY
₹ 1,27,270/-
PROGRAM
DEVELOPMENT
1 MONTH GENERATION OF
CODES FOR
COMMAND
OPERATION
NULL
TOTAL TIME= 7 MONTHS TOTAL COST= ₹ 1,27,570/-

13. PROJECT
APPLICATION
For Detecting
Intrusions into
Wide Entrances
to Work Areas
Safety Light
Curtains Enable
Horizontal
Presence
Detection.
Position-
detection
Muting is
Achieved for
Greater Work
Efficiency
Floating
Blanking
Fixed Blanking
Safety Light
Curtains with
Water-resistant
Cases

14. FUTURE
ENHANCEMENT
 It supports high level of reliability and pervasive attempts to make risk
free work environment .
 Reducing hazardous threats arising from unintended contact
between robots and humans.
 Improving overall performance of industrial robots.

15. CONCLUSION
 The use of industrial robots in manufacturing is becoming increasingly prevalent
worldwide. This is an emerging trend driven primarily by the push for greater efficiency
and higher productivity as well as falling robot prices, shortage of manpower and
increasing labour costs.
 Robots are essentially machines and the mechanical hazards typically experienced when
working with a machine apply also to industrial operations involving robots.
 Common mechanical hazards when using machines include entanglement, cutting,
crushing, impact, shearing and draw-in hazards.

16. REFERENCE
 KUKA Introduction to Robotics (Prof. Dr. -Ing. Eberhood Roos)
 KUKAAdvance Robot Programming for KUKA System Software Manual
 https://www.beckhoff.com/english.asp?ethercat/ek1100.htm
 https://www.sick.com/in/en/opto-electronic-protective-devices/safety-light-
curtains/c/g185751
 https://ab.rockwellautomation.com/Sensors-Switches/Operator-Safety/Light-Curtain