Application guide Flexi Soft - SICK Germany

Application guideFlexi Soft

Applications of the modular safety controllerFlexi Soft at machines and installations

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3 P R O D U C T S & A P P L I C AT I O N S A P P L I C AT I O N G U I D E F L E X I S O F T | S I C K 8013115/2010-03-01

safetyPLUS® – we solve safety problems

Safety solutions from SICK increase your security of investment,

open up new potential for savings due to more effi cient processes,

and always remain focused on the primary objective – the safety of

man and machine.

Rock-solid safety concepts for perfectoperational safety

safetyPLUS® provides a unique range of compe-tencies for the safety of man and machine. After all SICK is the world’s leading manufacturer of industrial safety systems and convinces with an impressive combination of competence, prod-ucts and services.

Water-tight system solutions for complete safety applications

Behind safetyPLUS® is the world’s most versa-tile product portfolio: A comprehensive safetypackage from safety switches through optoelec-tronic sensors to safe control solutions andnetworks. Simple and trouble-free in applicationfrom planning to worldwide usage.

4S I C K | P R O D U C T S & A P P L I C AT I O N S A P P L I C AT I O N G U I D E F L E X I S O F T8013115/2010-03-01

Unlimited potential for savings due tointegrated safety concepts

The unique cost-effectiveness of safetyPLUS®

saves time and money! This starts with theuncomplicated planning and carries on throughinstallation and commissioning to the actualproduction. Every SICK technology is as easy aspossible to use and will also be up to date infi ve years time.

Complete safety by means of servicesfor every day

The safetyPLUS® services: SICK experts adviseand assist from the fi rst plant walk-through,during the risk assessment and all the way tothe CE assessment - always compliant withthe latest standards and directives, and withthe SICK inspection seal for machinery andsystems. By the way: Every year SICK performs more than 10,000 safety inspections worldwide.


Further informations:

Product information

Data sheet

www.sick.com

Service you can depend on

With SICK you will always obtain optimal results in the

interaction between man and machine.

With SICK you have, in this sensitive area, a partner at your side whose innovationshave been setting international standards for more than 60 years; most recently withsafetyPLUS®, the all-round package for industrial safety.

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Application guide - Flexi Soft Page

Overview pageSafetyPLUS® – we solve safety problems 3

Your advantages – explained simply 6

Flexi SoftModular safety controller with a powerful software 8

Overview of Modules 10

Applications in detail 1)

Fishing boat 12

AGV 13

Wood scanner 14

Robot welding cell 15

Material loading of a vertical panel saw 16

Automated guided systemin a logistics center 18

Leak detection at fuel tanks 20

Double cell welding robot 22

Stretch film winder 24

Pneumatic press 26

Tyre fabric winder 28

Newspaper palletizer 30

Pop-up press 32

Metal plate milling machine 34

Test machine for computer chips 36

Robot cell for kitchen door lacquering 38

Beer barrel washing plant 40

Baking station for meat loaf 42

Ordering informationOrdering information 44

CD for the handbook 45

1) All applications are reference examples and has to get adapt to your special request.

More safety due to customised service!


Your advantages – explained simply

sens:Control - a new name for safe control solutionsThe new generation of safe control solutionsfrom SICK combines advanced technologies withease of use in every project phase. How doesit work? Very simply: SICK developed, from theground up, a new integrated product conceptthat was consistently designed for uncomplicatedusage.

A comprehensive range of engineer-ing and servicesSometimes it is a long way from planning toreality - but not with SICK! With sens:Controlthe selection is quick and the configuration sim-ple. In all phases of the project from planning,through commissioning to maintenance andupgrades to existing systems, we support youwith comprehensive services.


Overview

Flexi Soft

Applications in detail

Ordering information and CD

sens:Control – safe control solutions for a multitude of different industries

Safety and simplicity encompasses the solution for all branches and applications. The products range from making possible the simple integration of an Emergency Stop on a packaging machine, to the integration of optical

safety sensors with press contacts or the combination of entry/exit stations with entry protection in a logistics cent-ers and finally up to the networking of complex machines with one another, all with minimal engineering effort.

Safety relays • No logic • 1 - 2 inputs • Up to 2 x 2 outputs • Central solution

Safety controller Flexi Classic • Simple logic with 4 types of logic function blocks • 4 - 100 inputs • 4 - 52 outputs • Confi guration viascrewdriver • Central solution

Safety controller Flexi Soft • Medium to complex logic with 38 logic blocks • 8 - 96 inputs • 4 - 48 outputs • Confi guration viasoftware • Central solution

Network solutions • Medium to Complex Logic with 38 Logic Blocks • >100 inputs • > 48 outputs • Decentral solution


Modular safety controllerwith a powerful software

Flexi SoftSafety made easySteep learning curves and complicat-ed programming are no longer part of Machine Safety. Flexi Soft makes it so simple via the intuitive and ergo-nomic programming software.

With the Flexi Soft Designer, the entire project is programmed from beginning to end. The planning is done via PC and hardware is selected and combined to offer the optimal amount of inputs and outputs.

All tactile and optical safety sensors can be attached to these modules in order to complete the project.

Up to 12 modules can be attached to the chosen CPU and thereby up to 144 inputs/outputs can be used.

Due to the individual and compact 22.5 mm wide modules, the control cabinet only needs to house enough safety controller to match the appli-cation. On the next pages, the Flexi Soft Designers functions and which modules used for expansion will be described in detail.

Product description

• Shortened response time and therefore shorter distance from the hazardous point (8 ms) using Fast Shut Off makes possible the building of more compact machines

• Confi guration via intuitive software with a graphical user interface

• Logic editor with a comprehensive library of certifi ed function blocks

• Function block based logic editor Optimised integration via EFI (e.g. S3000, C4000)

• Integration in all leading net-works: EtherNet/IP, PROFIBUS-DP, CANopen, Modbus TCP, Device-Net, PROFINET IO

Customer use

• Low I/O count per module avoids the purchase of unused inputs and outputs

• Confi guration in the Memory Plug for a lightning quick commission-ing

• Intuitive software with wiring dia-gram and offl ine simulation

• Expansed sensor functionality via EFI

• Cost effi ciency: Shortend engi-neering time due to increased software ergonomics. Single-channel outputs reach SIL3, Ple


Overview

Flexi Soft



For further information and to download the designer free of charge,visit us at www.sens-control.com

Flexi Soft Designer

Hardware confi guration • Simple hardware configuration by drag & drop • Large selection on input and output elements with sym-bols that are easy to understand • Customer-specfic modification of elements which can be inserted into a special library • Simple transfer of elements and modules which have already been utilized • Context-specific help • Multi-language menu support (ie. G/En/Fr/Sp) • Online monitoring of the I/Os

Logic editor • Comprehensive library of 38 function blocks • 255 logic blocks are at the ready • Special function blocks for presses and Muting applica-tions are included • I/O summary for a concise overview • Offline simultation mode • Force mode to easy commissioning • Online monitor in the logic

Report and diagnose • Comprehensive report in one file • Wiring diagram included • Possibility to insert project description • Thorough diagnostics of all parts at all times • Detailed description to get to the root of the problem • Presentation of the configuration in graphical form • Multi-language fault text

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Multifaceted

Overview of Modules

Main modules • General function blocks (i.e. AND/OR/XOR/NOT) • Application-specifi c: Bypass, Muting, Press, etc. • RS-232 port for confi guration and real-time diagnostics • EFI connection for expanded sensor functionality, thor-ough diagnostics and bidirectional device communica-tion • FX3-CPU0: without EFI connection • FX3-CPU1: with 2 EFI connections • Separate memory plug to save the safety controller`s confi guration

In-/ Output expansion modules • FX3-XTIO: Input/output expansion with 8 safety inputs, 4 safety outputs and 2 test outputs • FX3-XTDI: Input expansion with 8 safety inputs and 8 test outputs • Up to 12 modules can be attached to the chosen CPU and thereby up to 144 inputs/outputs can be used

Relay expansion modules • UE410-2RO:2 normally open, 1 application diagnostic output and 1 EDM contact • UE410-4RO:2 x 2 normally open, 2 x 1 application diagnostic output and 2 x 1 EDM contacts • UE12-2FG:2 normally open and 1 EDM contact, cascade • UE10-2FG:2 normally open and 1 EDM contact

1 1S I C K | P R O D U C T S & A P P L I C AT I O N S A P P L I C AT I O N G U I D E F L E X I S O F T8013115/2010-03-01

Overview

Flexi Soft



GatewaysIn order to connect Flexi Soft to an existing PLC, it is pos-sible to integrate up to two Gateway. Using these gate-ways, I/O status as well as fault and status information can be read from and nonsafe process data can be writ-ten to the Flexi Soft. The contents of the process data can

be customized and the most frequently requested data is preconfigured out of the box.

The following modules are available: • EtherNet/IP FX0-GENT (1044072) • PROFIBUS-DP FX0-GPRO (1044075) • CANopen FX0-GCAN (1044076) • Modbus TCP FX0-GMOD (1044073) • DeviceNet FX0-GDEV (1044077) • PROFINET IO FX0-GPNT (1044074)

Product description

• Diagnostic module for connecting to an existing PLC

• Send and receive at least 50 Bytes of information

• Compact 22.5 mm width

• Confi guration via intuitive software with a graphical user interface

• Shortened failure discovery

• Acts as a bridge between two network protocols when two gateways are used

• Remote diagnostics and confi guration of Flexi Soft and attached EFI sensors via the Ethernet based gateways(Ethernet TCP/IP)

Customer use

• Diagnostics show the input status (HIGH/LOW) of all Flexi Soft modules as well as EFI devices

• Display of logic result status within the Logic editor

• Default and status information of all Flexi Soft modules

• Diagnostic data (i.e. I/O fault messages in text for-mat)


Fishing boat and AGV

E-Stop centralization for motors

The task On a fishing boat the winding motors which deploy and retract the fishing nets are to be fitted with E-Stops and safety switches. The monitoring of the emergency stop function will be cen-tralized and controlled by the appro-priate safety controller.

Realization The emergency stop function is cen-tralized within the Flexi Soft safety controller. There are two winding motors for fishing nets on each side of the fishing boat. In addition to the normal on/off functioning of the motors, there are two ES21 emer-gency stop pushbuttons and one i10 safety switch on each winding motor which minimize the danger for man and the machine.By activating the safety switch the motor will be safely shutdown. By the logical connection of the E-Stops and the safety switches associated with each side of the ship within the Flexi Soft safety controller, the emergency stop function is centralized.In order to offer the expected signal to the motors, four additional 4RO-Relay expansion modules are used to control them.Via a Reset button associated with each motor, the fishing net’s motor is reactivated. Especially useful is that the safety solution can be quickly configured and tested offline on the desk which avoids unscheduled dura-bility of the boat into the harbor, even if the number of motors is unknown.

Customer use • Centralization of the emergency stop function • Additional protection for man and machine • The powerful logic editor and the modular assembly assure a fast and worry free installation • The systems grows module by module with the application

SICK is continuously publish-ing examples of application solutions on the Internet

www.sick.com

Application at a glance

The task Safety automation

Industrial sector/branch Food & beverage

Applications/type of machine Fishing boat

Safety functions Emergency stop function

Product family Flexi Soft, ES21, i10


Additional information on www.sens-control.com

Overview

Flexi Soft



Reduced downtime forautomatically guided systems

The task In the automobile industry the work-ers should be protected of being hit by an automated guided vehicle (AGV) which transports motor blocks. Beside the protection by scanners, there has to be the possibility of an emergency stop.

Realization Lower downtime of an AGV can be achieved through use of safety laser scanners. The AGV has two directions of motion making two scanners nec-essary to avoid collisions.You can find one S300 Advanced safety laser scanner on the front and the back side of the AGV, installed just above floor level. They are con-nected to the Flexi Soft safety control-ler by the EFI interface. Their main task is the protection in each direc-tion of motion using an protection field. Only the protection field, which heads to the direction of motion, is active and gets switched to inactive via Flexi Soft if there is an change of the direction of motion. It’s thereby possible to traverse the track behind the AGV. The ES21 emergency stop pushbutton gets assembled on the top of the AGV, so that the worker could use it if it‘s necessary. There is an reset button installed, to actuate the AGV again.The Flexi Soft safety controller, inte-grated into the cabinet of the AGV, stops the AGV if the safety fieldis interrupted or the E-Stop has been pressed.

Customer use • Lower down time increases the availability • Protection fi eld switching increase ease of human machine interaction • The traverse of the track is possible behind the AGV • Due to it’s small size, the safety controller easily can be positioned inside the cabinet of the AGV


www.sick.com


The task Safety automation, Hazardous area protection

Industrial sector/branch Automotive & vehicle construction

Applications/type of machine AGV

Safety functions Emergency stop function, Reset/ Restart

Product family Flexi Soft, S300 Advanced, ES21


Wood scanner and Robot welding cell

Protection for a safe set upand servicing

The task In a sawmill single planks are indi-vidually tested for inconsistency and are sorted out using a wood scanning machine. The wood scanner must be protected against unauthorized access during regular operation.

Realization The wood scanner is surrounded by 4 access doors which are each protect-ed by an RE300 non-contact safety switch. The wood scanner only runs if all doors are closed. If one door is opened during regular operation, a safety switch is activated and the conveyor belt and wood scanner are switched off.In order to allow for service mode, an E100 enabling switch is used. In service mode, the switch off signal is overridden by the enabling switch and quick adjustments can be made at slow speed.Additionally, three dual-channel ES21 emergency stop pushbuttons are wired in series to switch off the machine if it is necessary. All con-nected sensors are attached to the Flexi Soft in which the signals are combined in the logic editor to switch off the machine safely.

Customer use • Assured service mode with an enabling switch • Safe access to the machine in service mode is assured • Compact safety concept for the entire machine


www.sick.com



Industrial sector/branch Wood, furniture

Applications/type of machine Wood scanner

Safety functionsEmergency stop function, Safety-related stop function, Differentiation between men and material (Muting)

Product family Flexi Soft, RE300, ES21, E100



Protective fi eld switching for increasing productivity

The task In the automotive industry two exchangeable containers are manu-ally filled next to a welding robot. These containers can be completely removed. Therefore the aperture has to be protected against unauthorized access.

Realization To increase productivity, it is neces-sary to install an S3000 Advanced safety laser scanner above the depot to protect the hazardous area around the robot.The EFI interface on the safety laser scanner and the Flexi Soft safety con-troller allow for a simultaneous protec-tion field monitoring. Both protection fields are constantly active, except when they are disabled due to a mut-ing condition via four WT24 sensors. This means that the wagon can enterand exit the depot without stopping the robot.If there is a person walking into the depot, the Flexi Soft safety controller detects the dangerous situation by the Muting sensors and stops the robot. The controller sees that a wagon isn’t interrupting the sensor, but rather that there is a abnormal motion. The Flexi Soft provides the interface for the S3000s EFI communication and inputs for the WT24 sensors and securely shuts down the robot in case of a danger. It controls the intrusions into both protected zones and evalu-ates the information from the muting sensors and S3000 to stop the robot.

Customer use • Space saving solution with only one safety laser scanner • Only one safety laser scanner, because the analysisof two simultaneous fi elds via the EFI interface is possible • Increased availability thanks to the simultaneous protection fi eldsand muting • Muting evaluates and differentiates between man and material


www.sick.com


The task Safety automation, Access protection, Ha-zardous area protection


Applications/type of machine Robot welding cell

Safety functions Differentiation between men and material (Muting), Emergency stop function

Product family Flexi Soft, S3000 Advanced, WT24

active inactive

Overview

Flexi Soft




Complete entry guardingof a dangerous area

The task On a panel saw large panels out of wood and plastic get cut individual or as a package. The three entry points have to be protected because it is possible for a worker to enter the area of the saw.The access and exit, through which the panels automatically reach the machine to get cut, have to be pro-tected. Thereby the controller has to detect if there are panels or a man entering the hazardous area. The accesses which are parallel to the conveyor belt have to be protected against unauthorised incidence while the going concern. Due to the high speed of the saw blade the trespass of the hazardous area would be especially dangerous. In case of an unauthorised switch off of the saw, areset is required.

Realization All three accesses to the machine are protected by a M4000 Advanced multiple light beam safety device. If a person or a subject reach the haz-ardous area, the machine switches off safely. Access to the entry and exit side of the saw’s conveyor belt is additionally monintored by Muting.On either side two WT24 sensors which take over the muting are attached. There are two M4000 Advanced multiple light beam safety device located on each side as well, which are both connected to the main module of the Flexi Soft safety


www.sick.com



Industrial sector/branch Wood, furniture

Applications/type of machine Vertical panel saw

Safety functions Differentiation between men and material (Muting), Emergency stop function

Product family Flexi Soft, M4000 Advanced, WT24

controller via the EFI interface. If something else than a panel enters the hazardous area, the connected WT24 sensors give the informa-tion to the Flexi Soft safety control-ler, which in turn shuts down the machine.The controller detects, that there is no panel on the conveyor belt, but an object or a person, which isn’t allowed to be there. The frontal access to the saw is protected by

a M4000 Advanced multiple light beam safety device which is con-nected to the expansion module of the Flexi Soft safety controller.Muting is not needed here, as noth-ing must enter the machine from this side. In case of an shutdown of the saw, a manual reset on the control cabinet gets required.

Material loading of a vertical panel saw



Used logic functions: • NOT, AND, OR, EXOR • Reset • Switch On Delay • Switch Off Delay • Edge Detection • 2 Sensor Muting • RS Flipflop • Interlock Monitoring

The description of how the used logic blocks work is found in the Flexi Soft Designer Software Us-ers Manual(8012480).

Customer use • Minimal space requirement due to the optimal use of the inputs and of the EFI interface • Decrease in downtime thanks to the muting function

Used modules: • Main moduleFX3-CPU1 • Expansion modulesFX3-XTIO

The complete configuration can be found on the CD included.

Overview

Flexi Soft



Hardware configuration

In/Out Summary Page


Automated guided systemin a logistics center

Increased productivity viamanual and automatic restart

The task An automated guided vehicle (AGV) on rails transports pallets from the palletizer to the packaging machine.The area around the rails is con-stantly traversed by the workers. For this reason the use of a conveyor belt wouldn’t be possible. To avoid a collision between the AGV and a worker or to eliminate the negligent use of the AGV as a personal means of transport, the AGV has to be pro-tected.If a worker climbs on the AGV, there must be an manual restart. Also the AGV has to stop, if any worker enters the hazardous area around the AGV. By leaving the hazardous area there will be a Restart after 2 sec, to avoid long downtimes. The palletizing machine and the packaging machinehave also to be secured against unauthorized access.

Realization The hazardous area around the AGV is protected by two S300 safety laser scanners, one on the left and one on the right side and two S3000 safety laser scanners, one at the front and one at the back side. The two safety laser scanners S3000 are connected to the Flexi Soft safety controller by the EFI interface. The two S300s are connected to the expansion module of the Flexi Soft.The simultaneous protection field detection offers an extra level of safety for the workers. By enter-ing the large protective field of the


www.sick.com



Industrial sector/branch Logistics

Applications/type of machine AGV

Safety functions Emergency stop function, Differentiation bet-ween men and material (Muting)

Product family Flexi Soft, S3000, S300, M4000, ES21

Logi

S3000 the AGV brought to a stop, however after two seconds there is an automatic Restart. If the smaller protection field of the S3000 is then interrupted, the AGV stops again but has to be restarted by a manual Reset as the worker is now too close to the AGV. To either side of the AGV, a protective field of the S300 pro-tects the area. Noone can enter the AGV and thereby enter the machine without tripping a field. The protec-tion fields of the four safety laser

scanners are active all the time, independent of which direction the AGV is heading. Finally, to stop the AGV in a hazardous situation there is an ES21 emergency stop push but-ton on the AGV.The protection of the entry to the palletizer is achieved through a sepa-rate safety controller in conjunction with a M4000 multiple light beam safety device. Additional two WL24 sensors are installed with their reflectors for the muting.



Overview

Flexi Soft



Used logic functions: • NOT, AND • Reset • Switch On Delay


Customer use • Simultaneous protection fi eld analysis via the EFI interface allows for an automatic and manualRestart depending on the situation • Minimized downtimes of the AGV thanks to an automatic Restart

Used modules: • Main moduleFX3-CPU1 • Expansion moduleFX3-XTIO

The complete confi guration can be found on the CD included.


In/Out Summary Page


Leak detection at fuel tanks

Wiring savings comparedwith previous solutions

The task In the course of quality control, tanks are checked for leaks though a test machine fitted with two inde-pendent testing stations. The tanks are manually inserted into the test control unit. Faulty tanks should be detected and separated before the delivery. Therefore the tanks should be identified by a bar code scanner and afterwards checked for leaks. After a passed test, the tanks are labelled.The unauthorized access during the current testing process should be secured by trap doors, which can only be opened when the machine is stopped. A service mode should be also possible if the doors are open. A manual stop of the machine must also be provided for a controlled stop.

Realization Both trap doors are protected by one RE11 safety switch. In this way the testing process can only start if the doors are closed. The testing stations are controlled separately, so that the testing process can start only after one door is closed. Simul-taneously, one can insert a new tank into the second testing place. If one door is opened, only the affected testing process stops.In service mode, one E100 enabling switch is located at each testing sta-tion. This switch provides a secured service mode of the machine and


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Applications/type of machine Leak detection at fuel tanks

Safety functions Emergency stop function

Product family Flexi Soft, ES21, RE13, E100

in the case of a hazardous situation stop the respective process station. By closing the trap doors afterwards, the testing process starts automati-cally.Additionally, the machine is fitted with a dual-channel ES21 emer-gency stop pushbutton. It has to be pressed to stop of the entire machine in the case of a hazardous situation. Therefore the emergency

stop pushbutton is installed right in the middle of the two testing sta-tions. If there is an emergency stop the machine, it starts again by push-ing the designated Reset pushbut-ton. The Flexi Soft safety controller collects the individual safety compo-nents and stops one or more parts of the machine depending on the hazardous situation.



Overview

Flexi Soft



Used logic functions: • OR • Reset • EDM


Customer use • Safe service mode by an enabling switch • Parallel operation by dividing the machine into two testing stations

Used modules: • Main moduleFX3-CPU0 • Expansion modulesFX3-XTIOFX3-XTDI • Relay expansion moduleUE10-2FG



In/Out Summary Page


Double cell welding robot

High productivity using two loading zones

The task A double cell welding robot handles workpieces at two independent turntables. The access is protected by fences on the right and left side. In one fence there is a service door. The operation is only possible if this door is closed.The entry points by which the worker can access the turntable are always open. Hence, the finished welded pieces of metal can be removed and a new one inserted only if the arm of the robot is in the other cell. The turntable has to be in a safe position as well. Otherwise the robot must stop if someone enters this area. The cell in which the welding arm is working may not be entered. Addi-tional it should be possible to manu-ally stop the robot in an hazardous situation.

Realization The access through the service door is secured by a i12S safety switch. If the door is opened, the robot and the turntables stop. The entry points used to exchange material are moni-tored by M4000 multiple light beam safety devices. Using two IN4000 non-contact safety switches, the position of the centre of the robot is determined. Therefore an inter-ruption of a particual entry point`s M4000 only stops the robot if the arm of the welding robot is in this area. The safe position of the each of the two turntables is detected by a non-contact safety switch IN4000. If the turntable and the robot are in a


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The taskSafety automation, Access protection, Hazardous area protection, Safe position monitoring

Industrial sector/branch Metal & steel production

Applications/type of machine Welding robot

Safety functions Emergency stop function, Reset/ Restart, Safe position monitoring

Product family Flexi Soft, IN4000, M4000, ES21, i12S

safe position, the worker can enter this area to change the part. All safety components are connected to the safety controller Flexi Soft, which safely controls the machine. If there is a complete stop of the robot, the dangerous action of the turntable will also stop.The switch-off signal is send directly from the safety controller Flexi Soft. After a complete stop, the Reset pushbutton has to be pushed to start the machine again. Additionally there

is one emergency stop push button ES21 on each access and on each service door which switches off the machine in a hazardous situation.



Overview

Flexi Soft



Used logic functions: • AND, OR • Reset


Customer use • Parallel operations are possible • Minimized cycle time because of reduced downtime • Highest level of safety for the worker through multiple protection

Used modules: • Main moduleFX3-CPU0 • Expansion modulesFX3-XTIOFX3-XTDI



In/Out Summary Page


Stretch film winder

Optimal light curtain integration via EFI

The task A high-performance thin film wrap-per has to be protected against unauthorized access. The pallets reach the thin film wrapper by con-veyer belt, where they are automati-cally wrapped by a thin stretch film. Finally, they are moved out of the machine and prepared for transport.At both ends of the machine it has to be assured that no worker can come into the winding area. This area is only accessable via two service doors, one of which is used to reload the thin film.If one of these doors is opened, or one of the accesses get entered by a worker, a reset is required. Amanual stop of the wrapper by the worker must also be possible.

Realization The access of the conveyor belt to the wrapper is protected using an M4000 multiple light beam safety device. Additionally there are mut-ing sensors used to make sure that only loaded pallets can enter the machine. If a person enters, the con-nected Flexi Soft safety controller detects this different movement and shuts down the machine securely. The access by which the pallets leave the stretch film winder, is pro-tected by a C4000 Palletizer safety light curtain. It detects the pallets profile as it’s leaving the thin film wrapper and shuts down the actua-tor if there is a different pattern.To change the thin film rolls, it is possible to entering a service door


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Industrial sector/branch Packaging

Applications/type of machine Stretch fi lm winder

Safety functions

Differentiation between men and material (Muting), Emergency stop function, Integration of safe automation into control system on different network (Gateway), Reset/Restart

Product family Flexi Soft, M4000, C4000 Palletizer, ES21, i10, WT24

which is protected by an i10 safety locking device. If the front door is opened, the actuators of the film changing machinery are stopped, so that the change of the rolls isn’t dangerous. If the back service door is opened, the machine’s wrapping motion stops immediately. After entering a reset is required in order to restart the machine.The Reset pushbuttons are on the control cabinet beside the service door. There is also an ES21 emer-gency stop pushbutton on each side,

through which a manual shut down of the machine is possible. All safety components are connected to the Flexi Soft safety controller.



Overview

Flexi Soft



Used logic functions: • AND • Reset


Customer use • Compact and fl exible control solution • Optimal sensor integration via the EFI interface on the main module of the Flexi Soft • Remote and continuous diagnose via Profi Net Gateway

Used modules: • Main moduleFX3-CPU1 • Expansion modulesFX3-XTIO • GatewayFX0-GPNT



In/Out Summary Page


Pneumatic press

Simplifi ed solution with the helpof the press function blocks

The task On the pneumatical press one can choose three operating modes using an user mode switch: A two-hand mode, where the two-hand con-troller must be pushed during the entire cycle, a single-break mode, by which the press starts automatically after one entry into the press and a double-break mode, which starts after two entries into the press. In all three operating modes the worker must be protected from the press using a safety light curtain. For the initial start-up in two-hand mode, a reset is required. If somebody inter-rupts the press, the press stops and a reset is once more required.Additional there is a service door, which is secured against unauthor-ized opening during the running ofthe press. After each switch-over into a new user mode, there must also be a reset required.

Realization The service door is protected by a safety locking device i10 Lock and can only get opened, if the press is stopped. The frontal access to the press where the work pieces are inserted and removed is protected using a C4000 safety light curtain in all operating modes. The start of the press results from pushing the reset button on the control cabinet for single and double break mode. In two-hand mode the two-hand but-tons must be pressed for the entire cycle. The Flexi Soft safety controller takes over the connection and the


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Industrial sector/branch Machine tool

Applications/type of machine Press

Safety functionsControl modes and operating mode selection, Emergency stop function, Machine controller, Reset/Restart, Safety locking function

Product family Flexi Soft, C4000, i10 Lock, ES21

controlling of all safety devices. In single-break mode, the press is acti-vated by a reset for the first cycle, as it is in the double-break mode. By interrupting the C4000 safety light curtain either once or twice depending on the mode the cycle starts anew. In this case the safety controller detects how often and how long the light curtain is interrupted. In the case of active PSDI time moni-toring, the maximum duration of an entire PSDI is limited to 30 sec. The Flexi Soft safety controller stops the

press upon unexpected access and a Reset is necessary. An access dur-ing the press cycle stops it directly. Additionally, the main valve and the remaining valves are controlled by the Flexi Soft and the movement of the press as well. Finally, an ES21 emergency stop pushbutton is installed outside the press which shuts down and switches it off in case of a hazardous situation.



Overview

Flexi Soft



Used logic functions: • OR • Reset • Two Hand Control(Type IIIA) • User Mode Switch • Press Single Stroke • Break Mode


Customer use • Ease of realization using certifi ed press function blocks in the Logic editor • Operating mode selection for an individual execution of the press process




In/Out Summary Page


Tyre fabric winder

Minimized downtimethrough a wide range of solutions

The task At a automotive supplier, freshly manufactured textil material is made using flow presses. The material is spooled on two rolls at the end of the machine. This material will be used to produce tires afterwards, where it will be combined with rub-ber. The rolls rotate slowly and take up the material.The hazard for the workers is that they can become caught up in a roll and trapped. If the rolls are full, they are rotated 90° so that they can be removed by a forklift. Afterwards a new roll can be placed there again. The hazardous rotating movement can hurt a worker and therefore access must be protected.

Realization Depending on the progress the mate-rial isn’t produced at a constant rate. However the rolls rotate at a constant speed. This causes some fabric fibres to fall to the ground. This situation shouln’t be result in a shut down. The monitoring of the area is only possible via three safety mats. Due to the light weight of the fabric they won’t activate the mat. The weight of a worker in contrast would activate the mat directly if he entered this area. In this case both rolls stop. Afterwards a manual restart is required from outside this area to restart both rolls. The remov-al area in which the forklift accepts the rolls is protected by two S3000 safety laser scanners which make


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Applications/type of machine Tyre fabric winder

Safety functions Emergency stop function, Reset/Restart

Product family Flexi Soft, S3000, ES21

sure that no worker is inside when the full rolls are removed. After tilting and removing the roll a manual reset is required even if the laser scanners have stopped the machine. Addition-ally there are four ES21 emergency stop pushbuttons that stop the roll actuators manually. These and all other safety components are con-nected to the Flexi Soft safety con-troller.



Overview

Flexi Soft



Used logic functions: • OR • Reset


Customer use • Smooth process without interruption




In/Out Summary Page


Newspaper palletizer

Productivity increasethanks to complete protection

The task In a robot cell, two robots arrange and palletize newspaper packages which enter the cell by conveyor belt. The packages are identified by a bar code scanner and either stacked on assigned pallets afterwards or, if they couldn’t get detected, sorted out by a robot. The rejected and the palletized packages leave the cell by a conveyor belt. These two accesses have to be secured, so that no worker can enter the cell through these accesses. Additional there are two service doors which have to be secured against unauthorized access while the machine is running. Finally, the space in the cell behind the robot has to be secured so that no worker can enter the working space of the robot above the fences around the cell.

Realization Both exits, through which the news-paper palletts or the sorted out packages leave the cell via conveyor belt, are each guarded by a C4000 safety light curtain. Both have two reflex muting sensors which allow newspapers but not workers through. The two safety doors are secured using an i10 Lock safety locking device. The access is only possible if both robots and the conveyor belts are switched off. Once this occurs, an entry button at the door can be pushed to unlock the interlock. Next to each of the doors there is an ES21 emergency stop pushbut-


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Industrial sector/branch Print & paper

Applications/type of machine Newspaper palletizer

Safety functionsDifferentiation between men and material (Muting), Emergency stop function, Reset/Re-start, Safety locking function

Product family Flexi Soft, ES21, C4000, S3000, i10 Lock, WT24

Top

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Flexi

Flexi

ton which causes the complete robot cell to switch off such that no hazardous situation possible. All safety components are connected to the safety controller Flexi Soft. The S3000 safety laser scanner is con-nected to this controller and is used to monitor the free space behind the robots in the robot cell. It is excluded that a worker might enter the cell by the conveyor belt, which delivers the newspaper packages from above. If the two robots and

the conveyor belts get shut down, a reset is required. The reset buttons are installed next to the ES21 emer-gency stop pushbuttons.



Overview

Flexi Soft



Used logic functions: • OR • Reset • EDM • Routing 1:N • Ausschaltverzögerung • 2 Sensor Muting


Customer use • Compact safety controller, in which the logic is implemented to enhance the productivity of the robot cell

Used modules: • Main moduleFX3-CPU0 • Expansion moduleFX3-XTIO



In/Out Summary Page


Pop-up press

Easy confi gurationvia press function blocks

The task A press which produces engine parts should be secured in such a way that the dangerous movement stops if somebody enters the press. The press handles five operating modes. Single stroke, in which a press cycle is initiated by a two-hand control and the service mode, in which the press get step by step moved by the two-hand push button. Additional to these two there are a single-break mode and a double-break mode, in which the next press cycle is initiated by reaching into the press once or twice. Finally, there is an auto mode in which the press is started by the pushing of a reset button and is stopped only when requested.In all five operating modes the secu-rity of the workers has to be assured as the press works with a pressure up to 80 tons.

Realization To control the press process the safety controller Flexi Soft is used. A C4000 safety light curtain is con-nected to this controller which is installed directly on the front of the press where the worker accesses it. It stops the press safely in each operating mode if there is an access to the Pop-up press. In the single- and double-break mode The safety light curtain is additional used to start the press cycle in single- and double-break mode if someone


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Industrial sector/branch Machine tool

Applications/type of machine Press

Safety functionsControl modes and operating mode selection, Emergency stop function, Machine controller, Reset/Restart

Product family Flexi Soft, C4000, ES21

reaches into the press one or two times respectively. Therefore noth-ing can be inside the protecting area of the press. Additionally, the safety light curtain detects if there is an unexpected access and stops the press. To shut down the press in a hazardous case an ES21 emergency stop pushbutton is installed on the press. This and the two-hand push-button, which is used in the operat-ing modes press single stroke, serv-

ice mode and auto mode to control the press, are also connected to the Flexi Soft. To start the press there is always a reset required. The reset is also required after each operating mode switch or after a shut down of the press. This reset pushbutton is mounted on the control cabinet.



Overview

Flexi Soft



Used logic functions: • AND, OR • Reset • User Mode Switch • Universal Press Contact • Two Hand Control(Type IIIA) • Clock Generator • Press Single Stroke • Press Set Up Mode • Break Mode


Customer use • Inside the safety controller Flexi Soft the logic of all operating modes is implementedusing preconfi gured press logic blocks




In/Out Summary Page


Metal plate milling machine

Two safety fi elds make continuousmilling and material swap possible

The task On a universal milling machine big metal plates are horizontally milled. Because the milling station is freely accessible and moveable, it has to be assured that no worker can be next to the milling head during a mill-ing process. At the same time there has to be the possibility for the work-ers to check the engaged workpiece without stopping the milling process. Therefore the milling machine has to be separated into two areas. Addi-tional there has to be the possibility to shut down the machine manually in a dangerous situation. The safety components have to be integrated into the machine controller, so that the status of the single components is available all the time.

Realization The milling machine is separated into two areas, right and left. If the milling head is inside of one of these areas, the access to the other area has to be possible without shutting down the milling process. Therefore the position of the mill-ing head gets detected by a IN4000 non-contact safety switch. During the position detection it’s assured that the access to one of the areas is possible, if the milling head is inside the other one. The complete access area round the machine is monitored by four safety laser scan-ners S3000, which are installed in the middle of each side right above


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Industrial sector/branch Metal & steel production

Applications/type of machine Milling machine

Safety functionsEmergency stop function, Integration of safe automation into control system on different network (Gateway), Safe position monitoring

Product family Flexi Soft, S3000, IN4000, ES21

the bottom. The safety laser scan-ners, the safety switches and four emergency stop pushbuttons ES21, which are installed at each angle, are connected to the safety control-ler Flexi Soft. Using the ES21 emer-gency stop pushbuttons ES21 there is always the possibility to manually initiate a safe shut down of the mill-ing machine. If an emergency stop is activated by one of the compo-

nents, a reset is required to start the machine again. The restart but-ton is on the control cabinet of the machine. The safety controller Flexi Soft is connected to the machine`s automation controller as well via a PROFIBUS-DP-Gateway, so that all states of the single components can be monitored.



Overview

Flexi Soft



Used logic functions: • AND, OR, NOT • Reset • EDM • Routing N:N


Customer use • Increased productivity using two protection fi elds, which are switched by the Flexi Soft • Integration of the safety controller via Gateway into the existing function control

Used modules: • Main moduleFX3-CPU1 • Expansion modulesFX3-XTIOFX3-XTDI • GatewayFX0-GPRO



In/Out Summary Page


Test machine for computer chips

Integration of the safety controllersdiagnostics in the non-safe controller

The task A machine used for testing computer chips’s thermal properties should be secured against the hazard of the unauthorized opening of service doors during the testing process and protecting the worker during load and unload of groups of chips. The machine is separated into two areas, the loading area and the process or thermal testing area.In the loading area the chips get inserted or extracted. From there they are transported to the process area, where they get tested for their thermal characteristics for three dif-ferent temperatures. Both areas are secured by loading or service doors. By opening one of these service doors or by pushing the emergency stop pushbutton a shut down of the machine should follow to pro-tect man and machine. The loading area only switches off the transport mechanism. The state of each door (open/ closed) should be monitored individually.

Realization The hazardous area of the trans-porting units inside the machine is already covered by doors. The machine is separated into the load-ing and the testing area, which are separated procedurally and secured by four doors. An i12S safety switch is installed at each of the eight doors.By opening one door of the testing area both parts of the machine stop.


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Industrial sector/branch Electronics

Applications/type of machine Chip testing machine

Safety functionsEmergency stop function, Integration of safe automation into control system on different network (Gateway), Safety locking function

Product family Flexi Soft, i12S, ES21

However, if a door of the loading area gets opened, only the hazard-ous transporting movements of the loading area stop. The test continues as switching off this area is time intensive and cannot be reached from the loading area.Additionally two ES21 emergency stop pushbuttons are installed to the machine. These stop the machine manually in a hazardous situation. The connection and control of the safety components is taken over by

the Flexi Soft safety controller.The information of the states of the machine is forwarded via an Ether-net gateway and can get evaluated this way. In this way one can monitor the status of each door and generate a reset signal using the HMI.



Overview

Flexi Soft



Used logic functions: • AND • Reset • EDM


Customer use • Separate monitoring of each of the safety components via the Ethernet gateway • Use of single relays is not necessary • 50 Bytes status information via the gateway increases the availability • Low downtime by separating the machine into to areas

Used modules: • Main moduleFX3-CPU0 • Expansion moduleFX3-XTIO • GatewayFX0-GENT



In/Out Summary Page


Robot cell for kitchen door lacquering

Non-stop production via safety buffer zone

The task A robot cell for kitchen door lacquer-ing is separated into three areas, the material loading, the lacquering area and the material unloading. The lacquering area is accessible by two locked service doors. The material loading and the unloading area can be accessed by workers.The rest of the machine is secured by fences. As long as the robot arm is not in the material loading area, this area is freely accessible for the workers. The same is true for the unloading area. The lacquering area cannot be accessed at any time unless the machine is securely shut down.

Realization The position monitoring of the robot arm is monitored by three IN4000 non-contact safety switches.Both doors are barred by an i10 Lock safety locking device and can only be unlocked if the robot has stopped. In addition there are four ES21 emer-gency stop pushbuttons located at the access to the robot cell, one on each service panel to stop the robot in a hazardous case.The material loading is secured by two C4000 safety light curtains, one at the beginning and the end of this area, as well as an M4000 Area mul-tiple light beam safety device, which is installed horizontal at the lower area and is used as an area guard-ing. If the robot arm is inside this area, the activation of the first light curtain or of the M4000 Area cause


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Industrial sector/branch Wood / furniture

Applications/type of machine Lacquering robot

Safety functions Emergency stop function, Safe position moni-toring

Product family Flexi Soft, S3000, M4000, C4000, IN4000, i10 Lock, M4000 Area, ES21

A B

C

to a shut down. If it is in one of the other areas, the light curtain board-ing area A secures the area around the robot.The unloading area is secured in similar fashion, except that the multiple light beam safety device is replaced by two S3000 laser scan-ners as because this area is sepa-rated into two separate monitoring zones. The zone nearest to the robot is always enabled, the other one is switched on as needed. All safety

components are connected to the Flexi Soft safety controller, which shuts down the robot in a hazardous case. In case of shutdown a reset is required, which occurs from outside the cell.



Overview

Flexi Soft



Used logic functions: • AND, OR, NOT • Reset • Routing 1:N • Interlock Monitoring


Customer use • Lacquering process doesn’t have to be disrupted at any time, hence a higher productivity is assured • Workers can access the area where the robot is not actively working without shutting it off, thereby increasing productivity

Used modules: • Main moduleFX3-CPU1 • Expansion modulesFX3-XTIOFX3-XTDI



In/Out Summary Page


Beer barrel washing plant

Complete machine protection

The task An industrial washing plant for the automatic cleaning of beer barrels should be protected. In this machine, beer barrels between 10 L and 60 L are transported into the machine by a conveyor belt.From there the beer barrels reach an automatic washing plant and pass through the cleaning process.Finally, they are loaded onto pallets. These can be then removed by a forklift. During the complete process it has to be avoided that a worker can enter the machine. While the machine is running, pallets with bar-rels have to be inserted for cleaning and clean barrels must be removed all without stopping the machine. Additional all safety components have to be monitored and diagnosedindividually.

Realization The area, at which the barrels get inserted, is protected by two C4000 safety light curtains. These allow new beer barrels to enter the machine without causing shutdown but no person can enter. The clean-ing process is protected mechani-cally such that there is no access for the worker.After the washing process ends, the barrels are discharged from the machine. This area is accessible by two doors, which are each pro-tected by an i10 safety switch. The area, where the pallets are removed from the machine, is protected by a C4000 safety light curtain.


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The task Safety automation, Access protection


Applications/type of machine Beer barrel washing plant

Safety functions

Differentiation between men and material (Muting), Emergency stop function, Integration of safe automation into control system on different network (Gateway), Reset/Restart

Product family Flexi Soft, M4000, ES21, i10

This assures that no worker can come inside a running machine, but that the pallets can be removed by forklift. The machine is also fitted with 11 ES21 single-channel, or dual-channel emergency stop push-buttons, depending on the needed category, so that a manual shut down of the machine is possible in a hazardous situation. All safety components are connected to the Flexi Soft safety controller. A Flexi Soft PROFIBUS-DP Gateway is used to monitor the individual safety com-

ponents.If one area is shut down a reset is required. For each area reset buttons are installed at the machinehousing.



Overview

Flexi Soft



Used logic functions: • AND, OR, NOT • Reset • Routing 1:N


Customer use • Compact safety solution for the complete machine • Easy implementation of the complex logic • Transmission of the status and the situation of all safety devices to the automation controller (PLC)via PROFIBUS-DP

Used modules: • Main moduleFX3-CPU1 • Expansion modulesFX3-XTIOFX3-XTDI • GatewayFX0-GPRO • Relay expansion modulesUE410-4RO



In/Out Summary Page


Baking station for meat loaf

Worry free implementationof complicated logic

The task A baking station for meat loaf is filled with baking trays by hand. These pans are taken from a convey-or belt placed into the machine one at a time. There they are consecu-tively baked, tilted to remove the left over grease and then finally offload-ed after they pass the cooling sta-tion. While the machine is running, the access doors cannot be opened without stopping the machine. The insertion of the baking pans into the entry can only be possible between cycles, even if the conveying system is running. Additionally there should be the possibility to start each cycle manually so that adjustments to the machine can be made.

Realization The entry to the baking station is protected by a C4000 safety light curtain, which shuts down the conveyor belt if a pan is inserted midcycle. If a pan is inserted, there is an expected cycle start then no reset is required. If a pan is inserted during the baking process, a reset is required. Additionally, an i110RP rope switch is installed above the entry which stops the machine manually in a hazardous case. The access to the machines individual baking sections is protected by doors at the walkway side. These are monitored by an RE31 non-contact safety switch or an i10 Lock safety locking device. At the side facing the wall, access through a service door is also secured by an i10 Lock.


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Applications/type of machine Baking station for meat loaf

Safety functionsEmergency stop function, Integration of safe automation into control system on different network (Gateway), Safety locking function

Product family Flexi Soft, C4000, E100, i10 Lock, RE31, ES21

Access through this door results in a controlled stop with braking. In this way the current cycle is stopped and a safe restart inhibit is assured. At the walkway side, there are two E100 enabling switches, so that the machine can run in service mode even though the doors are opened. The floor above the machine is sepa-rated into two areas, the baking and cooling section. The access is pro-tected by a door with an i10 safety door switch each. If one of the doors is opened while the machine is run-ning, the respective area is switched

off. Access to the baking and cooling sections are also secured with doors. An L41 Single Beam Light Switch is mounted in front of these doors, monitors if any doors are opened and finally initiates a switch off com-mand to the respective drive when one is opened. A reset is only possi-ble when all the doors are closed. All components are connected with the Flexi Soft which signals the stop in a hazardous case.



Overview

Flexi Soft



Used logic functions: • AND, OR, NOT • Reset • RS Flipflop • Two Hand Control(Type IIIA) • Switch On Delay • Clock Generator


Customer use • The complex logic requires a sophisticated software-based safety controller • Complete coverage of the machine, separated into different areas

Used modules: • Main moduleFX3-CPU1 • Expansion modulesFX3-XTDIFX3-XTIO • GatewayFX0-GPRO



In/Out Summary Page


Ordering informationand CD to the guide

Ordering information

Main moduleNumber of EFI interfaces Type Order number

– FX3-CPU000000 10437831)

2 FX3-CPU130002 10437841)

1) The memory plug is ordered separately.

System plugDescription Type Order number

Memory Plug FX3-MPL000001 1043700

Expansion modulesNumber of inputs Number of outputs Connector types Type Order number

8 single-channel4 single-channel Dual level spring clamp set FX3-XTIO84002 1044125

– Dual level spring clamp set FX3-XTDI80002 1044124

GatewaysFieldbus Type Order number

EtherNet/IP FX0-GENT 1044072Modbus TCP FX0-GMOD 1044073PROFINET IO FX0-GPNT 1044074PROFIBUS-DP FX0-GPRO 1044075

CANopen FX0-GCAN 1044076DeviceNet FX0-GDEV 1044077

Relay expansion modulesNumber of normally

closed contactsNumber of application

diagnostic outputsConnector types Type Order number

2 1Pluggable terminals UE410-2RO3 6026144Dual level spring clamps UE410-2RO4 6032677

4 2Pluggable terminals UE410-4RO3 6020143Dual level spring clamps UE410-4RO4 6032676

2 –Screw type terminals, fi x UE10-2FG2D0 1043915Screw type terminals, variable UE10-2FG3D0 1043916

2 –Screw type terminals, fi x UE12-2FG2D0 1043917Screw type terminals, variable UE12-2FG3D0 1043918

Accessories

Description Order numberConnection cable 2m 6021195Connection cable 10m 2027649Adapter from USB to RS-232, UC-232A 6035396Screw terminal set (4 pcs.), FX3 2045891Dual level spring clamp set (4 pcs), FX3 2045890


Overview

Flexi Soft



For further information and to download the designer free of charge,visit us at www.sens-control.com

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S34 Worldwide presence with

subsidiaries in the following countries:

AustraliaBelgium/LuxembourgBrasilCeská RepublikaChinaDanmarkDeutschlandEspañaFranceGreat BritainIndiaIsraelItaliaJapanNederlandNorge

ÖsterreichPolskaRepublic of KoreaRepublika SlovenijaRomâniaRussiaSchweizSingaporeSuomiSverigeTaiwanTürkiyeUnited Arab EmiratesUSA/Canada/México

Please fi nd detailed addresses and additional representatives and agencies in all major industrial nations at www.sick.com

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Factory automation

With its intelligent sensors, safety sys-tems, and automatic identifi cation appli-cations, SICK provides comprehensive solutions for factory automation.

Logistics automation

Sensors made by SICK form the basis for automating material fl ows and the optimization of sorting and warehousing processes.

Process automation

Optimized system solutions from SICK ensure effi cient acquisition of environ-mental and process data in many indus-trial processes.

Our Business Segment Expertise

• Non-contact detecting, counting, classifying, and positioning of any type of object

• Accident protection and personal safety using sensors, as well as safety software and services

• Automated identification with bar-code and RFID reading devices for the purpose of sorting and target control in industrial material flow

• Detecting volume, position, and con-tours of objects and surroundings with laser measurement systems

• Precise measurement of gases, liquids and dust concentrations for continuous monitoring of emissions and the acquisition of process data in production processes

• Gas flow measurements with maxi-mum accuracy thanks to compact gas meters

SICK AG | Waldkirch | Germany | www.sick.com

Application guide Flexi Soft - SICK Germany

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