All-in-One – Safety with motion monitoring
Wieland enables comprehensive motion monitoring with the expanded functions within the samos PRO COMPACT basic module.
Nowadays, the increasingly profound digitalization and automation allows companies to respond more efficiently, more quickly and more flexibly. The increasingly dynamic nature of processes and production sequences, however, also involve tougher requirements for the safety of man and machine. Against this background, Wieland Electric has upgraded its safety controller samos PRO COMPACT and made it fit for motion monitoring.
No matter whether machines, systems, autonomous vehicles, lifts or wind turbines – wherever movement is involved, there can be no compromise on safety. As processes become increasingly automated, the monitoring of motion continues to gain importance. This can be optimally achieved using safety controllers. The very reason why Wieland now has all functionalities needed for comprehensive rotational speed, rotational direction and position monitoring integrated in its samos PRO COMPACT.
Wide-range motion monitoring
The new Plus variant of the samos PRO COMPACT safety controller has six functions for reliable speed, position and direction monitoring. The motion sensors detect the required pulses up to 70kHz, which the controller converts to speed, angle, position and direction. The motion functions, which are implemented according to EN 61800-5-2, compare the actual values with the limit values: If a permissible limit value or range is exceeded, appropriate safety measures come into effect. Allowing the motor to be safely stopped, doors to be closed or locked, or even an additional alarm to be triggered.
The major benefit of this functional expansion: Numerous safety functions can be realized with just one sensor element. Each functional module covers up to 4 ranges. In one controller, up to 25 rotational speed monitoring functions can be called up. This allows up to 100 speed or position ranges to be monitored by one basic module. In addition, the flexible units for limit values are proving to be extremely practical for international use of the samos PRO COMPACT PLUS. Both the international SI standard system and the Imperial and US customary measurement system can be used.
Sophisticated functions for trouble-free operation
With asynchronous motors in particular, fluctuations among the axes are due to the weak control. The solution is a hysteresis that can be configured for each range and set to counter vibrations. This is precisely what the samos PRO COMPACT PLUS module from Wieland offers. As soon as the entered value enters the inner zone, the enable sets to "High". When the outer zone is vacated, the enable is returned to "Low". This prevents frequent switching at the fluctuation points to achieve a very high efficiency and availability of the system.
For trouble-free operation of machines, systems or wind turbines, serious damage such as shaft breaks or excess rotational speeds in bad weather should also be detected. The Wieland safety controller is able to do this by means of a speed comparison. The Plus module of the samos PRO COMPACT controller contains scaling factors for synchronizing the two sensors or axes and provides flexible comparison methods for two motion sensors. This also includes the absolute tolerance for position monitoring, the relative tolerance based on the actual rotational speed and a combination of the two methods for initial accelerations. Additionally, a comparison with and without direction, for counter-rotating rolls for example, can be performed as an option.
Professional fault diagnosis and maximum safety
Each motion function of the samos PRO COMPACT safety controller offers a convenient reset. This is required to acknowledge faults and inform the user that the fault has been resolved. The reset debouncing time can be configured easily via the samos PLAN 6 programming tool. Optionally, the fault outputs can also be displayed. This indicates whether the fault is global, sensor-related or function-related. Relaying the fault message to lamps, HMI ECO panels and a PLC allows a fast fault diagnosis, which reduces standstill times and increases the productivity of the system.
The optional manual restart is another additional safety factor. If the motor is safely stopped when a safety area is vacated, it is necessary to decide how to reactivate the motor. With an automatic restart, the motor starts without any further user intervention. Alternatively, however, "manual restart" can be selected. In this case, the system returns to the safety area only if the user responds accordingly. The required restart variant can be individually set for each function block via the software. The debouncing time can also be configured.
To be able to realize different operating modes as well, the controller offers optional bypass and muting functions. The operating mode switch also allows the bypass function to be activated in "Operation" and deactivated in "Service" mode, or use Safe Limited Speed only used in "Service" mode.
Unique safety level thanks to incremental encoder
The reliable SENC incremental encoder with HTL interface from Wieland Electric is available as an accessory. This allows speed and angle at the axes to be reliably measured, thereby achieving an unparalleled safety level to PLe and SIL3. It is suitable for all the reliable speed, direction and position monitoring of all machines with referencing run and for automatic guided vehicles (AGVs). The SENC incremental encoder is available in sizes 58mm and 90mm with hollow and solid shafts and with the matching accessories.
The programming tool: Simple, intuitive and license-free.
samos PLAN 6 provides PLC programmers, electrical engineers and developers with tried and proven, powerful programming software without the need for a license. The tool is capable of intuitive operation thanks to automatic hardware configuration. It has a comprehensive library with TÜV-certified function blocks. The forcing function allows the machines to be quickly restarted despite faulty sensors. The software tool also conveniently delivers configurable project documentation at the touch of a button.
With the professional programming tool from Wieland, mean values can be calculated via a configurable measurement interval. As a rule, the measurement interval influences the reaction time, the system behavior with peaks and the measurement accuracy. At the same time, short measurement intervals lead to correspondingly shorter reaction times, while long measurement intervals cause longer reaction times and better filter short peaks. samos PLAN 6 automatically calculates the measurement accuracy at each limit value to ensure professional and transparent project planning of the system.
Compact power pack: Wieland has continuously developed its samos PRO COMPACT safety controller and allows, with expanded functions within the basic module, comprehensive motion monitoring.
The safety functions of samos PRO Compact PLUS at a glance:
• Standstill monitoring
• SLS – Safe Limited Speed
• SSR – Safe Speed Range
• SSM – Safe Speed of rotation Monitoring
• SDI – Safe Direction
• SLP – Safe Limited Position
Because separate function blocks are not required, the SOS, SS1 or SS2 functions can be very easily achieved in a samos PLAN 6 project.