With the advancement and vigorous development of the concept of Industry 4.0, machinery and equipment are assisting or replacing personnel to complete the product production and processing process more efficiently and with high precision, and at the same time, the high-speed moving parts of machinery and equipment may cause different degrees of injury to operators. Countries and regions around the world have regulations and standards in place to ensure that all machine builders are aware that machines must meet strict safety requirements to protect workers from injury.
As an important part of modern equipment, servo motors cooperate with the different safety functions of servo controllers (servo amplifiers) to maintain the normal operation of the machine while providing safety guarantees for the operator, which will greatly reduce people's impulse to bypass safety functions and "run red lights". Many operations that previously required a shutdown and restart can now be done with the machine continuing production at a reduced speed or even at full speed. Functional safety ensures operator safety and maximizes machine productivity. In practical use, the servo controller can provide more safety function options in addition to the STO safety function, and we will select a few for you to explain in detail and explain the practical application scenarios.
1. Safe torque off
The safety function "STO" shuts off the power supply to the motor from within the servo control and the motor is in an uncontrolled stop state in accordance with the stop category 0 in accordance with EN 60204-1.
Application scenario: After the STO safety function is activated, the motor is in a torque-free state and does not cause any dangerous movement, which is suitable for urban scenery and equipment where the motor can be stationary or reduced to a speed range that does not produce danger for a short time when the safety function (emergency stop, safety gate) is triggered. However, if the motor will fall due to the gravity of the component itself when it moves vertically, it is necessary to increase the brake holding mechanism in order to prevent personal injury caused by gravity falling.
2. Safe stop 1
The safety function "SS1" brakes the motor under control, monitors the deceleration of the motor within a specified range, and activates the STO function to cut off power to the motor after a certain delay or when the speed threshold is reached. The motor is in a controlled stop state according to the stop category 1 of the standard EN 60204-1.
Application scenario: After the SS1 safety function is activated, the motor is in a controlled stop or deceleration and then enters the STO state to avoid dangerous movement, which is suitable for when the safety function (emergency stop, safety gate) is triggered, the motor cannot stand still in a short time (high speed or large component inertia) or avoid product scrap or additional risks caused by incomplete process flow. However, the peripheral safety protection device needs to have a delayed opening function, such as the safety door switch needs to have a locking function, after the door opening request is issued, the controller can first send a stop signal to the servo controller, and the safety door switch can be unlocked to enter the dangerous area after the motor enters the STO state.
3. Safe Operating stop
The safety function "SOS" is used to monitor the stationary state of the motor, which is able to maintain torque output and be stationary, rather than an external brake (e.g. brake) to achieve a stationary state.
Application scenario: After the SOS safety function is activated, the motor will be in a controlled stationary state, which is suitable for the situation that when the safety function (emergency stop, safety gate) is triggered, the motor needs to be in a stationary state and cannot cut off the power supply.
4. Safe stop2
The SS2 safety function controls the motor to brake, monitors the deceleration of the motor within a specified range, stops the motor, and activates the SOS function to monitor the stationary state of the motor. The motor is in a controlled stop state with a continuous power source according to the stop category 2 of the standard EN 60204-1.
Application scenario: After the SS2 safety function is activated, the motor will stop and monitor the stationary state, which is suitable for the situation that when the safety function (emergency stop, safety gate) is triggered, the motor needs to be stopped in a controlled state and cannot cut off the power supply.
5. Safe limited speed
The safety function "SLS" prevents the motor from exceeding the set speed limit.
Application scenario: After the SLS safety function is activated, the motor is not allowed to run beyond the speed value set by the servo controller. Suitable for use in specific situations (e.g. manual or service mode) where after the safety function (safety gate) is triggered, personnel must enter the danger zone and use the enable button to operate the moving parts at low speeds.
6. Safe direction
The SDI safety function prevents the motor from moving in the wrong direction.
Application Scenario: When the SDI safety function is activated, the motor can only be allowed to run in the set direction. Suitable for use in specific situations (e.g. manual or maintenance mode) and when safety functions (safety doors, light curtains) are triggered, the motor can only move in a safe direction (away from the operator).
Functional safety is a way to ensure the safe operation of machines, it does not force the separation of operator and machine motion control, it allows for safe interaction between operator and machine movement, even when power is on, it can also help to achieve continuous operation under safe constraints and thus increase productivity.
Automation specialist Pilz has a wealth of experience in the industry and can provide users with complete and safe motion control solutions.
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