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TTechnology pur I COVERSTORY

EMERGENCY STOP

VIA WLAN How SIGMATEK bridged the gap and with the new »HGW« hand-held operating device series, is bringing a mobile as well as wire-less HMI solution with integrated Safety functions to the market

With the »HGW« series, the Salzburg automation technology provider SIGMATEKlaunches the next generation of mobile handheld operating devices. The HMI panels, which communicate via WLAN, are equipped with a 10.4“ color touch screenand with 1,300 g, they weigh just slightly more than the current cable-connectedversion; despite the integrated battery pack. The wireless devices give the operatornew freedom – they can move within the surroundings of the machines and systems without having to worry about the cable length. In addition to the transfer of function-oriented data, it will be later possible in a second variant to even send Safety data via WLAN. For this purpose, the HMI is equipped with emergency stopand confirmation buttons, as well as a key switch. Safety-relevant data is exchanged over the standard WLAN network using the »Black Channel« principle.

W ireless is in – not only in the con-sumer world. In every productionhall, cables prove to be notorious

trip hazards and can be a cost factor that shouldnot be underestimated. Since if damaged –when driven over for example – can lead to amachine stop or long maintenance times. Ope-rating machines and systems using a mobileHMI device is nothing new. Whereby in the in-dustry, the definition of »mobile« can almost beconfusing – after all, though most so-called mobile operating devices may be portable byhand, the action radius is decidedly limited by

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the predefined cable length. With wireless HMIs,machine operators can specify the location in thesystem they want to view themselves. During use,having to drag the cable along is also inconve-nient. The local manufacturer SIGMATEK seescomfortable and literally, unbound as well as fatigue-free operation as essential. One thing isclear however: The power source must be contai-ned in the wireless application. Finding the opti-mal balance between battery life and weight istherefore crucial. In full operation, the new SIGMATEK operating panel »HGW 1031« can runat least two hours without recharging. And de-spite the powerful battery, the convenient HMIweighs only 1,300 g – a flyweight. Further deci-ding criteria with the use of wirelessly communi-cating devices are the availability and datathroughput of the wireless network. Since todaypractically all consumer products operate over2.4 GHz WLAN, the »HGW 1031« supports the2.4 GHz as well as 5 GHz frequency band. Depending on the environment and distance requirement, users can determine the ideal solution themselves.

Unbound Machine Operation with Safety

„The »missing link« in the industrial context iswithout a doubt, a compact and Safety-orientedsolution for the reliable, wireless operation of machines and systems“, Franz Aschl, InnovationsManager from SIGMATEK is sure. „Market-readysolutions for Safety via WLAN have been aroundfor several years. Until now however, the serialapplication on industrial machines has failed be-cause of two factors – namely on the size of theavailable systems and most of all, their high costs.

We have recognized this unsatisfactory situationfor many manufacturers. With the new »HGW«series, we are introducing wireless WLAN hand-held operating devices to the market which willbe available without and – in a second variant –with the much-desired emergency stop functionvia radio signal.“ In addition to the transmissionof function-oriented data, the next generation of»HGW 1031« devices will also transmit Safety data via WLAN. The handheld operating device istherefore equipped with an emergency stop andconfirmation buttons, as well as a key switch. Safety-relevant data is transferred using to the

Black Channel principle overthe standard wireless net-work. No manufacturer ordevice-specific protocols aretherefore required. Safetydata are automatically sentto the »Safety« controller ofthe I/O and control series »S-DIAS« from SIGMATEKand appear like a perma-nently wired emergencystop as a digital input.

„The »missing link« in an industrial context is withouta doubt, a compact and Safety-oriented solution for the reliable, wirelessoperation of machines and systems.“

Franz Aschl, InnovationsManager at SIGMATEK.

Fits well in the hand: Thenew wireless »HGW 1031«handheld operating panelfrom SIGMATEK with 10.4“ touch screen.

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Emergency Stop Function via WLAN

Based on the Black Channel principle, the trans-mission of Safety-oriented signals via WLAN isproblem-free. However, for unrestricted use inthe wireless network, there are aspects thatshould be considered. Such as interruption-free

transmission for example. „Above all, the bit error probability of the transfer medium whichplays an equally important role in wired devices,is normally higher during wireless transmission“,explains Franz Aschl further. „The bit error pro-bability during wireless transmission is around10-3 – in comparison, this is improved by two exponents with a twisted-pair cable and reaches

a value of only 10-5.“ For this reason, this fact isof particular importance during radio transmissi-on. Whereby the Safety-oriented protocol, themaximum number of participants and the trans-mission cycle are deciding factors. Another newtask is logging the panel into the assigned machine before operation. „This is especially im-

portant when transferring Safety data, becausethis connection is not forced through a cable viahardware, but via the Safety application pro-gramming“ emphasizes Franz Aschl. „Loggingoff before leaving the machine environment andshutting down is equally important. If the con-nection to the integrated emergency stop buttonis lost, the Safety control – as with a cable break

– must assume that a Safety-related problem hasoccurred and stops the machine.“ SIGMATEKcreated the required mechanisms during deve-lopment of the device software, in order to en-sure that in setup mode, the view to the machi-ne is free or that a specific WLAN panel alwaysconnects with the designated robot. This equally

applies to the integration of system componentsthat are not always available or active.

What the Safety Norms Say About Emergency Stop via WLAN

The increased mobile and wireless use of machi-nes also brings new aspects in the current Safetynorms. To date, it has been presumed that an accessible emergency stop button will alwaysperform its intended function: bring the machineto a safe standstill. What happens now however,when on a non-functioning mobile device withno power, such as an operating panel or driver-less transport system, the emergency stop buttonis pressed? Are the additional system compo-nents in the defined area then brought to a safestandstill? The new points in the EN ISO13850:2016 cover exactly these applications. Toavoid confusion between an active and inactiveemergency stop triggering element, such as theemergency stop button, a change in the ele-ment's color via lighting the active emergencystop element must be made. SIGMATEK's newWLAN handheld operating device with Safetyelements therefore has and actively lighting

TTechnology pur I COVERSTORY

The WLAN handheld operating panel has an active lighting emergency stopbutton. When it lights red, the HMI clearly indicates that the emergency stop function is available and the Safety system is connected correctly.

The Safety solution from SIGMATEK is modularly constructed and easily adaptableto the respective on-site infrastructure andnetwork configuration. The monitoring timefor secure data transfer (latency time) can be set from 0 to 5,000 ms.

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emergency stop button (certified according to EN ISO13850), which reduces the risk of an operating error. If theoperating panel is not connected to a machine, system com-ponent or robot, this is clearly visible through the »grey«,unlit button. When the mobile HMI is correctly connectedor logged in, the emergency stop button lights in red (LED)and thereby clearly indicates that the emergency stop button is functional and the Safety system connected correctly.

HMI with a Future

Mobile, as well as relocatable machines and system compo-nents are a particular challenge for automation technology.This begins with the limited space conditions, since the automation solution is often installed – without a controlcabinet – directly into the mobile unit. Compact and stream-lined control solutions with low power consumption and reduced loss are in demand – and will only be more so in thefuture. „Transmitting all information and process data viawireless connection – even Safety-oriented data – will beco-me normality“, says Franz Aschl looking to the future.„Functions in the compact Safety CPUs that were to dateunimaginable, will play an important role in mobile and in-telligent machine connections; such as VNC, web server,OPC-UA, data recording, file transfer, E-Mail, PDF creationor intelligent axis control for example. And of course, therequirements from the machine guidelines must always bemet.“ The wireless HMIs from SIGMATEK raise the applicati-on dynamics for machine operation today to a new level.Operators can use the existing WLAN infrastructure in thefactory and run multiple machines, system components, robots and driverless transport systems with a single mobi-le panel. "This leads to obvious cost savings", emphasizesFranz Aschl. WLAN and cable-connected operating devicesof the HMI series from SIGMATEK can also be combined asdesired. Users can profit from the flexible adaptability of their HMI solution to the needs of the respective appli-cation. “Existing applications can also be reused in the mo-bile HMI variants“, adds Franz Aschl. "With the use of ournew, portable, approximately DIN A4 size »HGW« opera-ting panels, machine manufacturers expand the scope offunctions and application possibilities of their machines andsystems, and are a decisive step ahead of the global com -petition." (r.PA./TR)

INFOLINK: www.sigmatek-automation.com

I TOPIC

Safety Solution for »Industry 4.0«

Highly flexible manufacturing andhandling concepts with intelligent pro-duction resources, which can automati-cally adapt their configuration to chan-ged requirements, place new demandson functional Safety in »Industry 4.0«.The path leads from the mostly hard-ware solutions of today to flexible bus-integrated, programmable Safety systems. In addition to higher flexibili-ty, the remarkably simpler wiring onthe machine also has valuable benefits,since the safe signals are transmittedover greater distances via the existingsystem bus. Through the OPC-UA com-munications protocol, the extensiveand uncomplicated exchange of infor-mation between cooperative safe unitsis also brought into direct proximity.

Integrated or Stand-alone

With the compact and modular controland I/O system »S-DIAS« from SIGMATEK,Safety requirements can be implemen-ted flexibly and economically. Safety isthereby an integral part, the »S-DIAS Safety« components can also be used asa stand-alone solution. The transfer ofdata between multiple Safe controllersusing Black Channel via TCP/IP enablesthe implementation of cascaded stand-alone architectures. CPU, Safety control-ler and Safety I/O modules measure only12.5 mm in width, 104 mm in height and72 mm in depth. High-performance, fully programmable Safety solutions canbe thereby implemented within a widthof 37.5 mm. The solution meets thenew est Safety norms (SIL3 in accordancewith IEC 62061 and PL-e/Cat.4 accordingto EN ISO 13849-1/-2). The user-friendlysoftware »LASAL SAFETY Designer« enables fast project development in aclearly designed graphical editor.Theunderlying library provides PLC -open-based Safety function blocks, such

as »Emergency Stop«, »Two Hand Con-trol« or »Guard Locking« for example.The toolkit-like construction ensuresconsistent, error-free programming andquickly guides the user to clean docu-mented results.

Modular in Every Sense

The »S-DIAS Safety« system providesthe option to log system components inand out. This is the basis for a flexiblereconfiguration of machines duringoperation, as well as ensuring safehandling with partial systems that – forexample via WLAN – are wirelessly con-nected. A big advantage of this Safetysolution is its fully modular constructi-on and simple adaptability to the on-si-te infrastructure and network configu-ration. With »S-DIAS«, the monitoringtime for the safe data transfer can befreely set from 0 to 5,000 ms. The usercan therewith define the optimal set-ting with respect to actual latency timefor any application.

ExhibitionTIP

At the »SPS IPC Drives« trade fair in Nur -emberg, SIGMATEK will present amongother things, a mini Safety system withina control cabinet width of only 25 mm.In addition, dual-core CPUs as well asfunction modules for temperature, resis -tance and absolute pressure measure-ment expand the »S-DIAS« system.

»SPS IPC Drives«: Hall 7, Stand 270

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