Post on 03-Jul-2015
description
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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GuardLogix Integrated Safety System
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 2
Agenda
I talk a little more about Integrated Safety
You ask some more questions
You ask some questions
I talk a little about Integrated Safety
You give me a good review
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Description
Integrated safety is changing the way people think of safety system design
- safety systems that actually improve productivity. This session will
discuss and demonstrate how simple an integrated safety system is to
develop and maintain using Rockwell Software® Studio 5000. This session
is geared toward beginner to intermediate users and anyone interested in
understanding how integrated safety really works.
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Safety System Design Goals and Challenges
Goal:
Providing a machine that is safe to install / operate / maintain
Comply to appropriate standards (ISO 13849-1:2006, IEC 62061, …)
Challenge:
Deliver a safe, compliant system without compromising the production capability and flexibility of the overall system.
Deliver a system with capability for expansion and upgrading.
Deliver a system with global support capability
Deliver a system with adaptability and scalability
Design for Recovery - Minimize MTTR – Downtime or Service time
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Questions
How do I find the right mix of safety and productivity?
How does that machine need to act to be productive and safe?
Asking these two questions is relatively new…
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Traditional Contemporary Safety Solutions
Turns machine off
Hardwired Diagnostics
Inter-connect relays for
logic
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Hardwired Auxiliary Inputs
Safety Relay Configurable Safety Relay Stand-alone Safety PLC
E-Stop #1
E-Stop #5
E-Stop #3
E-Stop #2
E-Stop #4
Out Feed Conveyor
In Feed Conveyor
Some zone control
Hardwired Diagnostics
“Programs with a
screwdriver”
Multi-zone control
Comms link for Diagnostics
Programs with separate
software
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
• Two diverse PLCs
• 1oo2 implementation
• From a Safety perspective, this is a good design
• Costly, complex, highly engineering system
• Difficult to design, develop, test, and maintain
• Requires cross-wiring, cross-checking, extensively programmed diagnostics
Ch A
Ch B
Early Safety System Designs
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Still Have Challenges…
Additional hardware / programming for Safety System Diagnostics
Additional equipment to specify, purchase, hold as spare parts, …
Multiple software programming environments
Extra time to develop
Extra time to troubleshoot
Extra time to maintain
Additional training for maintenance personnel or for end customer
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What if we used a single PLC for Safe and Standard Control?
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
GuardLogix® Safety Integration Overview
Logix Integrated Safety
Dual Processor Solution (1oo2 Architecture)
SIL-3 Certification per IEC 61508
ISO 13849 Performance Level e (Category 4)
Programs with Studio 5000 Logix Designer
Safety I/O on Ethernet/IP
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
GuardLogix Features
Some provide separation
Some provide integration
Some just make integration „easier‟
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Separation between Safe and Standard Control
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Separation / Safety Task
Safety task created whenever a
GuardLogix safety controller is
selected
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 13
Separation / Physical Memory
• GLX Primary Controller has separate • Physical Memory for Standard Task Control
• Physical Memory for Safety Task Control
• Safety Signature • Memory for Safety Task
• Read Only
• No Forcing
• No Online editing
• No Offline editing
• Safety Lock • Prevents deletion of
safety signature
• Password protection
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Safety Task Scan
Safety Task is a Periodic Task
At period rate, Primary „wakes up‟ Partner
Safety input data „frozen‟; does not change during scan
Primary sends raw input data to Partner
Both Primary and Partner execute safety logic to completion using the frozen safety input data
Safety Task results are cross checked by both controllers (primary >< partner)
If results are OK, Primary and Partner each build half of the safety output data packet, and then packet is written to the safety outputs
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Separation / Safety and Standard Tags
Every controller tag has a class; either „standard‟ or „safety‟
Safety tags can only be used within safety task
Cannot „drive‟ or „control‟ a safety output tag in standard task
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Separation / Safety I/O
To create safety rated I/O tags, you need to use safety rated I/O modules
Safety I/O data automatically mapped into safety memory
CompactBlock™ I/O
(1791)
ArmorBlock® (1732)
POINT Guard I/O™
(1734)
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Separation / Unique Safety Protocol
GuardLogix communicates to standard I/O modules using CIP protocol
GuardLogix communicates to safety I/O modules using CIP Safety protocol
CIP Safety Protocol
Data is sent twice (redundancy)
One regular / One inverted (diversity)
Every packet is time stamped (diagnostics)
Protect against misuse; standard module data cannot appear in safety tags
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Separation / Safety Task Instructions
Instruction Category Supported Instructions Array/Shift Bit XIC, XIO, OTE, OTL, OTU, ONS, OSR, OSF, Compare LIM, MEQ, EQU, NEQ, LES, GRT, LEQ, GEQ Compute/Math File Misc. COP Filter For Input/Output GSV, SSV Math Conversion ADD, SUB, MUL, DIV, MOD, SQR, NEG, ABS Move/Logical MOV, MVM, AND, OR, XOR, NOT, CLR, Program Control JMP, LBL, JSR, RET, SBR, TND, MCR, AFI, NOP Select/Limit Sequencer Special Statistical Timer/Counter TON, TOF, RTO, CTU, CTD, RES
Only certified instructions available for safety task
Only certified instructions in Partner firmware
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Dual Channel Application Instructions
Next generation of certified application instructions
DCS is base instruction (Stop)
Stop with Test
Stop with Test & Lock
Stop with Test & Mute
Monitor
Start
Focused on three main safety “Functions”
Start
Stop
Monitor
Easier to use
Functions are built into the instructions
Test & Unlock Request
Hazard Stopped
Input Status
Reduces testing & validation effort
Better diagnostics
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Muting Suite and Safety Mat
3 Certified Muting Instructions
Two Sensor Asymmetrical
Two Sensor Symmetrical
Four Sensor Bidirectional
Safety for Conveyor related
applications
Light Curtains
Laser Scanners
Safety Mat Instruction
Eliminates the need for a safety
mat controller.
Directly connect safety mats to
safety input modules.
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Metal Forming Instruction Suite
BG Certified Mechanical Press Application Instructions
EN 692
ANSI B11.1
CSA Z142.02
10 Metal Forming Instructions Crankshaft Position Monitor
Clutch Brake Inch Mode
Clutch Brake Single Stroke Mode
Clutch Brake Continuous Mode
Camshaft Monitor
Main Valve Control
Auxiliary Valve Control
Manual Maintenance Valve Control
Two Hand Run Station
8 Position Mode Selector
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Integrate Safe and Standard Control
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Integration / Mix standard and Safety I/O
CIP and CIP Safety protocols can reside on same network
Ethernet/IP
DeviceNet
Can mix & match standard and safety Point I/O modules in the same rail
Differences between CIP and CIP Safety are at the protocol level, so you can communicate to standard and safety modules via Netlinx
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Integration /Mapping Tool
Standard tags can be directly mapped to safety tags
The Safety tag can then be used in safety task
This mapped safety tag must still be considered non-safety data
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Integration / AOI Signature ID
AOI functionality available for use within Safety Routines
Only safety tags / instructions are allowed
Safety Signature added to easily verify that AOI
downloaded properly.
Signature ID represents CRC of binary code in memory
Reduces test and validation effort
Test once and then simply verify signature on
each re use.
Transportable between GuardLogix projects
SIL integrity is maintained
Uses the same procedures as standard side AOI‟s Compatible with all future AOI enhancements
(Library ease of use features, etc.)
Provides users significant benefits
Helps enforce consistent behavior Reduces the risk of users creating custom logic
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Integration / Data Type added for P/C
Connection_Status data type added to support P/C Safety tags
Only UDTs can be used for P/C safety tags
First member must be CONNECTION_STATUS
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Integration made easy
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Ease of Integration / Standard Task Operations Same as ControlLogix®
• Executes each program top to bottom
and then restarts
• Operates at the lowest priority on the
controller
• Uses all CPU time left after other tasks
execute
• Interrupted by operating system to
perform processor and
communications overhead
• Traditional PLC Scan
• Triggered automatically at a preset
time interval
• Interrupts lower priority tasks and can
be interrupted by higher priority tasks
(15 Levels)
• Will time-slice on a 1ms basis with
another task at the same priority level
• Captures fault for task overlap
• Similar to PLC/SLC Selectable Timed
Interrupt (STI)
• Triggered on arrival of input,
consumed tag, motion operations, via
another program, or a Windows Event
for SoftLogix™ 5800
• Priority same options as Periodic...
• Captures fault for task overlap
• Similar to PLC Peripheral Input
Interrupt (PII) or SLC Discrete Input
Interrupt (DII)
Continuous Task Scan Periodic Task Scan
CP
U O
verh
ead
Tim
e-sl
ice
Task
Au
to-r
esta
rt
Scan interrupted by periodic and event tasks
Program 2
Program 1
Program ..n
...
Program 2
Program 1
Program ..n
...
5ms 10ms
15ms ...
Depending on task priority scan interrupted by other periodic and event tasks
Event Task Scan
Program 2
Program 1
Program ..n
... Input
Motion
Code ...
Depending on task priority scan interrupted by other periodic and event tasks
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Ease of Integration / Single Programming Tool
The real benefit is related to software familiarity
The more safety is the same as standard, the easier it becomes
Can program both safety and standard tasks using Rockwell Software® Studio 5000
Data structures remained the same
How I/O is handled remained the same
How communications are handled remained the same
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RSLogix™ 5000
V1…16,17,18,19,20
Studio 5000 Logix Designer™
V21,22,23,24,25,…
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Ease of Integration / Studio 5000 Logix Designer Safety Environment
Safety Controller
Status
Safety Instruction
Palette
Periodic Safety
Task, Programs,
Program scoped
safety tags,
Routines
Safety I/O
Safety Watermark
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
GuardLogix Integrated Safety
Integrated safety should reduce system development costs
Ease of use is the primary factor
Directly correlates to speed, less wasted time and effort
Common software reduces acquisition costs, but the real benefit is
related to software familiarity.
The more safety is the same as standard, the easier it becomes
How data is used in the system
How I/O is handled
How controller interlocking is done
Standard, Safety or both
How communications are configured and operate
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Improved Productivity via Safety System Design
Global Compliance – design scalable
applications that meet global
requirements.
Reduce Design Time – safety can not
continue to be an added cost solution, it
must deliver value.
Reduce Installation Cost and Start-up
Time – leverage existing investments
and architecture.
Safety = Productivity = Profitability
Modern Safety Practices are Enabling a Fundamental Change in How Safety is Viewed in Manufacturing
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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