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Key Tips for Using and
Operating Safety Networks
Thank you to our Sponsor:
Before We Start
 This webinar will be available afterwards at
designworldonline.com & email
 Q&A at the end of the presentation

 Hashtag for this webinar: #DWwebinar
Moderator

Presenters

Leslie Langnau

Tom Elswick

Corey Morton

Design World

Siemens

B&R Automation
International field bus and safety standards for factory automation
PROFIBUS covers both
factory & process automation
PROFINET - based on
standard ETHERNET - is its
complementary network
• 1999 first specification for safety
communication called PROFIsafe.
• PROFIsafe has evolved to become the
leading and most comprehensive safety
communication technology in the world.
• Developed to IEC 61784-3-3, PROFIsafe is
now the International Standard
• Evaluated by TUV and BGIA
The “PROFIsafe” Protocol
• Safety messages transmitted on existing
standard bus cables in coexistence with the
standard messages.
• Total independence from the base
transmission channels be it copper wires,
fiber optics, wireless, or backplanes
Safety measures include:

The “Black Channel” principle

• The consecutive numbering of the
PROFIsafe messages ("sign-of life")
• A time expectation with acknowledgement
("watch-dog")
• A codename between sender and
receiver ("F-Address")
• Data integrity checks (CRC =
cyclic redundancy check)
PROFIsafe message format
Certified Safety Output
CH A Pulse Check
Output Signal

Positive switched

Data
CRC

001100011100 uP
uP 1

1

O

One
Output
channel

0
Read back

Decentralized
I/O

Ground Switched

uP 2
Input data

Read back

CPUs Cross Check Each Other!
Failsafe I/O modules protect locally & simplify the design and wiring,
Even if the PLC and Network Fail, the I/O Module can go into Safety Lockout
Siemens Safety Integrated Solution
Siemens fail-safe I/O platforms
From standard to fail-safe automation in 3 easy steps
Detect

Evaluate

Respond

Standard
controller
Sensors

I/O

CPU and program

I/O

Standard CPU
Standard I/O

Hardware and firmware upgrades
Fail-safe I/O modules

Step 1

Hardware/firmware

F-CPU

Step 2

Communication

Standard communication
via PROFIBUS or PROFINET

Step 3

User program

program

F

Detect

Fail-safe
controller

Sensors
&
F sensors

F- CPU and program
&
F program

PROFIsafe
Safety program
STEP 7 and Distributed Safety

Standard program
STEP 7

Evaluate

I/O
&
F I/O

Actuators

Respond

I/O
&
F I/O

Actuators
Safety Application - Implementations
Industry, Automotive – Application, Robotics

Industry, Material Handling – Application, Gantry
Safety Application – Design & Implementation tips
Determination of safety level for each safety function

For all your safety needs:
www.usa.siemens.com/safety

Safety Evaluation Tool

www.siemens.com/safety-evaluation-tool
openSAFETY
The open safety standard for all industrial
Ethernet solutions
Concept of Integrated Automation
• One Bus for IO and Motion
Concept of Integrated Safety
• One Bus for IO and Motion and
SAFETY
Safety Market Overview
• Available Safety Protocols
o
o
o
o
o

ProfiSafe
CIPSafety
Safety EtherCAT
Safety Net p
openSAFETY

is limited to Profibus and Profinet
is limited to EtherNet/IP and SERCOS
is limited to EtherCAT
is a proprietary protocol from PILZ
is open and available for any fieldbus

• openSAFETY is fully open and totally independent of the
fieldbus!
Concept of openSAFETY
• Any Brand - Any Bus - One SAFETY standard
your HMI
brand

any
SAFE
PLC

your
PC
brand

your
PLC brand

Your
PANEL
brand

your IO brand

your motion
brand
Safe line communication
openSAFETY
• Independent, 100% open, and License free technology
• Approved as worldwide standard IEC61784-3
• TÜV certified protocol – IEC61508/11 SIL3, PL e, Cat 4
• One single Safety Standard for the complete production line
Reference Model
• openSAFETY includes all necessary services and interfaces to the
Safety Application
Communication Model
• openSAFETY makes use of the producer / consumer
communication model
Communication Model
• openSAFETY provides an extended version of the producer / consumer
communication model allows the producer to produce separated data
for individual consumers
Communication Model
• openSAFETY server client communication. Mainly used for
configuration services and network management
Errors and Preventive/Corrective Measures
• No faults go undetected !
Frame Structure
• The frame consists of two sub frames and is able to transport data up
to 254 bytes of payload data
Total Flexibility
• openSAFETY domain and gateway allow the safety through different
network architect
openSAFETY for Component Manufacturer
• One time development investment
o same safety standard for all fieldbuses

• Reduced development time
o Certified openSAFETY stack available

• Investment security
o legal and technical independence
o open source protocol stack

• Easy certification
o TÜV certified conformance test
o guaranteed interoperability
Key Tips for Using and Operating Safety Networks
Questions?
B&R Automation

Design World

Leslie Langnau
llangnau@wtwhmedia.com
Phone: 440-234-4531
Twitter: @DW_RapidMfg

Corey Morton
corey.morton@br-automation.com
Phone: 770-772-0400

Siemens

Tom Elswick
tom.elswick@siemens.com
Phone: 770-625-5762
Thank You
 This webinar will be available at designworldonline.com & email
 Tweet with hashtag #DWwebinar

 Connect with


Twitter: @DesignWorld



Facebook: facebook.com/engineeringexchange



LinkedIn: Design World Group



YouTube: youtube.com/designworldvideo

 Discuss this on EngineeringExchange.com
Key Tips for Using and Operating Safety Networks

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Key Tips for Using and Operating Safety Networks

  • 1. Key Tips for Using and Operating Safety Networks Thank you to our Sponsor:
  • 2. Before We Start  This webinar will be available afterwards at designworldonline.com & email  Q&A at the end of the presentation  Hashtag for this webinar: #DWwebinar
  • 3. Moderator Presenters Leslie Langnau Tom Elswick Corey Morton Design World Siemens B&R Automation
  • 4. International field bus and safety standards for factory automation PROFIBUS covers both factory & process automation PROFINET - based on standard ETHERNET - is its complementary network • 1999 first specification for safety communication called PROFIsafe. • PROFIsafe has evolved to become the leading and most comprehensive safety communication technology in the world. • Developed to IEC 61784-3-3, PROFIsafe is now the International Standard • Evaluated by TUV and BGIA
  • 5. The “PROFIsafe” Protocol • Safety messages transmitted on existing standard bus cables in coexistence with the standard messages. • Total independence from the base transmission channels be it copper wires, fiber optics, wireless, or backplanes Safety measures include: The “Black Channel” principle • The consecutive numbering of the PROFIsafe messages ("sign-of life") • A time expectation with acknowledgement ("watch-dog") • A codename between sender and receiver ("F-Address") • Data integrity checks (CRC = cyclic redundancy check) PROFIsafe message format
  • 6. Certified Safety Output CH A Pulse Check Output Signal Positive switched Data CRC 001100011100 uP uP 1 1 O One Output channel 0 Read back Decentralized I/O Ground Switched uP 2 Input data Read back CPUs Cross Check Each Other! Failsafe I/O modules protect locally & simplify the design and wiring, Even if the PLC and Network Fail, the I/O Module can go into Safety Lockout
  • 7. Siemens Safety Integrated Solution Siemens fail-safe I/O platforms
  • 8. From standard to fail-safe automation in 3 easy steps Detect Evaluate Respond Standard controller Sensors I/O CPU and program I/O Standard CPU Standard I/O Hardware and firmware upgrades Fail-safe I/O modules Step 1 Hardware/firmware F-CPU Step 2 Communication Standard communication via PROFIBUS or PROFINET Step 3 User program program F Detect Fail-safe controller Sensors & F sensors F- CPU and program & F program PROFIsafe Safety program STEP 7 and Distributed Safety Standard program STEP 7 Evaluate I/O & F I/O Actuators Respond I/O & F I/O Actuators
  • 9. Safety Application - Implementations Industry, Automotive – Application, Robotics Industry, Material Handling – Application, Gantry
  • 10. Safety Application – Design & Implementation tips Determination of safety level for each safety function For all your safety needs: www.usa.siemens.com/safety Safety Evaluation Tool www.siemens.com/safety-evaluation-tool
  • 11. openSAFETY The open safety standard for all industrial Ethernet solutions
  • 12. Concept of Integrated Automation • One Bus for IO and Motion
  • 13. Concept of Integrated Safety • One Bus for IO and Motion and SAFETY
  • 14. Safety Market Overview • Available Safety Protocols o o o o o ProfiSafe CIPSafety Safety EtherCAT Safety Net p openSAFETY is limited to Profibus and Profinet is limited to EtherNet/IP and SERCOS is limited to EtherCAT is a proprietary protocol from PILZ is open and available for any fieldbus • openSAFETY is fully open and totally independent of the fieldbus!
  • 15. Concept of openSAFETY • Any Brand - Any Bus - One SAFETY standard your HMI brand any SAFE PLC your PC brand your PLC brand Your PANEL brand your IO brand your motion brand
  • 17. openSAFETY • Independent, 100% open, and License free technology • Approved as worldwide standard IEC61784-3 • TÜV certified protocol – IEC61508/11 SIL3, PL e, Cat 4 • One single Safety Standard for the complete production line
  • 18. Reference Model • openSAFETY includes all necessary services and interfaces to the Safety Application
  • 19. Communication Model • openSAFETY makes use of the producer / consumer communication model
  • 20. Communication Model • openSAFETY provides an extended version of the producer / consumer communication model allows the producer to produce separated data for individual consumers
  • 21. Communication Model • openSAFETY server client communication. Mainly used for configuration services and network management
  • 22. Errors and Preventive/Corrective Measures • No faults go undetected !
  • 23. Frame Structure • The frame consists of two sub frames and is able to transport data up to 254 bytes of payload data
  • 24. Total Flexibility • openSAFETY domain and gateway allow the safety through different network architect
  • 25. openSAFETY for Component Manufacturer • One time development investment o same safety standard for all fieldbuses • Reduced development time o Certified openSAFETY stack available • Investment security o legal and technical independence o open source protocol stack • Easy certification o TÜV certified conformance test o guaranteed interoperability
  • 27. Questions? B&R Automation Design World Leslie Langnau llangnau@wtwhmedia.com Phone: 440-234-4531 Twitter: @DW_RapidMfg Corey Morton corey.morton@br-automation.com Phone: 770-772-0400 Siemens Tom Elswick tom.elswick@siemens.com Phone: 770-625-5762
  • 28. Thank You  This webinar will be available at designworldonline.com & email  Tweet with hashtag #DWwebinar  Connect with  Twitter: @DesignWorld  Facebook: facebook.com/engineeringexchange  LinkedIn: Design World Group  YouTube: youtube.com/designworldvideo  Discuss this on EngineeringExchange.com