Fewer service operations and increased plant availability thanks to Safety Device Diagnostics

Intelligent, networked production processes can significantly increase productivity. However, this is only possible if a wide variety of data is available. Safety Device Diagnostics can provide support. Our diagnostic solution supplies detailed diagnostic data.

Document changes, reduce downtimes

The diagnostic solution from Pilz records diagnostic data such as individual serial numbers, version status, current states and past error states. These are scanned and processed at control level via Modbus or Profibus. In future this will also be possible via Profinet or Ethernet/IP. This data is then displayed on the fieldbus module, the monitor of a PLC or on a computer screen via web server.

As a result the diagnostic data is available both on the machine and via remote access. You can use it for predictive maintenance. This is becoming increasingly important in the wake of Industrie 4.0. It applies not only with regard to the timely replacement of worn parts, but also to maintaining operational safety. Using the stored data you can compare the original state with the current state at any time. That way you'll discover any changes on the machine right away. Without any additional hardware at control level!

The Pilz diagnostic solution supports a modular approach

Another example for Industrie 4.0 scenarios are intelligent solutions for the functional safety of modular plants. The diagnostic solution's linear cable structure makes it comparatively easy to add another module to the plant. There's no need for any new cabling, changes in the control cabinet or changes to the design drawings. Nor are any additional safety devices required. In combination with the secure safety gate system PSENmlock, for the first time safety gates can be controlled individually. If a plant requires maintenance work or a tool change, it is possible to define which gates may be opened after shutdown. Without Safety Device Diagnostics, all the gates would open!

IO-Link Safety as an alternative

An alternative approach is currently being developed with IO-Link Safety. This guarantees interoperability right up to the sensors. So it operates on all levels with safety devices of various manufacturers. Data is transferred securely from the sensor to the PLC, creating new application options. With IO-Link Safety it is the PLC that switches and not the sensor. Expensive safety architectures are specified as a result and new dependencies arise between the sensor and PLCs, for example when a replacement is needed.

This approach is based on point-to-point connections, i.e. on a star configuration in the field or control cabinet, as it were. The bottom line is that both installation and engineering costs are considerably higher than with the diagnostic solution. Depending on the application, the cost-benefit ratio will be the primary factor in deciding which system will gain acceptance. Conclusion: IO-Link Safety is currently still a vision for the future – our diagnostic solution is ready to use now. Smart diagnostics from Pilz for the factory of the future!

Further information:

Safety Device Diagnostics