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COMPACTplus

Application Examples

Overview

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Safeguarding of Control Signals by Using the Additional Safety Circuit Sequential Muting with Detection of Persons in unallowed Areas Control of Partial Muting Zones on Run-Time by 2 Sensors

Leuze electronic | COMPACTplus Application Examples | 10/2007

Safeguarding of Control Signals (1/3) Problem and Solution:  Safe activation of a function in COMPACTplus by safety circuit at L3/L4, that monitors in parallel to (de-)activating a function the correct timing and short circuit protection  Changeover is safe if L3 and L4 are controlled by a manual action, but NOT by a standard PLC +24V L3 0V L4

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Example: Activation / Deactivation of reduced resolution 2-level change-over switch connected to L3 and L4, where polarity changes simultaneous One of the signals is used additionally as control signal for reduced resolution OSSD is off  

when the safety circuit is open in case of simultaneousness errors or short circuits at L3/L4

Leuze electronic | COMPACTplus Application Examples | 10/2007

active protected field reduced resolution

Protective field 1

Protective field 2

Safeguarding of Control Signals (2/3)

SafetyLab Settings:

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„Basic I/O Configuration“: 2-channel Safety circuit L3 and L4 Safety circuit is considered as closed in both positions  L3=0V and L4 = 24V  L3=24V and L4 = 0V OSSD are on in both switch positions, as long as the protective field is free

Leuze electronic | COMPACTplus Application Examples | 10/2007

Safeguarding of Control Signals (3/3)

SafetyLab Settings:

 Protective field editor: Select beam zone with reduced resolution

 Define L3 or L4 as control signal for reduced resolution L3

Leuze electronic | COMPACTplus Application Examples | 10/2007

Sequential Muting with Detection of Persons in unallowed Areas (1/5) Problem:  On the same body shop line in the car industry short and long car body are produced (for example VW Golf and Passat)  The robot cells are protected by light curtains with sequential muting  Muting sensors must be adjusted at the long body to make the application run  Persons behind the short body could thus get undetected into the danger zone  These Persons shall be detected

Area behind the body carrier forbidden for persons Leuze electronic | COMPACTplus Application Examples | 10/2007

Sequential Muting with Detection of Persons in unallowed Areas (2/5) Solution:  Positioning of muting sensors, when the carrier (blue) is shorter than the body (gray)  Detection of the feet of a person using a beam signals over a beam zone at the bottom, i.e. definition of a Beam Signal just for some beams at the bottom side of the light curtain  Evaluation of the Beam Signal only with a certain combination of sensor signals, i.e. at a certain position where the short body has ended and the long body is still in the curtain

MS1 MS2 (L3) (L1)

MS3 MS4 (L2) (L4)

Leuze electronic | COMPACTplus Application Examples | 10/2007

Sequential Muting with Detection of Persons in unallowed Areas (3/5) Solution:  Checking for persons (feet) behind the body when MS1 is free and muting is still active, i.e. evaluation of the Beam Signal only when MS1=free; MS3 and MS4 = interrupted  Muting stays active as long as NOT: (MS1 = inactive) & (MS3 = active) & (MS4 = active) & (Beam Signal = active = Person detected)

Beam Signal Zone

Start position of beam signal evaluation

Leuze electronic | COMPACTplus Application Examples | 10/2007

End position of beam signal evaluation

Sequential Muting with Detection of Persons in unallowed Areas (4/5) SafetyLab Settings:  Select 4-Sensor sequential muting in „Basic I/O Configuration“  Activate restart Interlock in „Start/restart“  Set parameters in „Indication signal combination“ for evaluation of sensor signals and a beam signal with output of the result for example to M4 as muting enable signal:

L3=MS1 Beam Signal 1 L2=MS3 L4=MS4

Leuze electronic | COMPACTplus Application Examples | 10/2007

& M4

Sequential Muting with Detection of Persons in unallowed Areas (5/5) SafetyLab Settings:  Control and indication signals: M4=Output (i.e. read back and linked with OSSD) Parametering in „Muting“:  Muting enable signal for example M2 with connection to M4 in the end cap  „Premature muting end after releasing the protective field“ activated with Time delay

M2

Leuze electronic | COMPACTplus Application Examples | 10/2007

M4

Control of Partial Muting Zones on Run-Time by 2 Sensors (1/6) Problem:  On a conveyor line pallets with different load heights are moving to a wrapper station  The wrapper is safeguarded by a light curtain with muting  The pallets can be distinguished in low load and high load types  On low load pallets persons could sit and drive into the danger zone  Those persons shall be detected while high load pallets shall pass

low load Leuze electronic | COMPACTplus Application Examples | 10/2007

high load

Control of Partial Muting Zones on Run-Time by 2 Sensors (2/6) Solution:  In the high side protective field a beam signal prevents muting -> partial muting  There is one pair of muting sensors at the low side to mute the bottom part  There is another pair of sensors at the high side to enable high load pallets to pass

high side

low side

Leuze electronic | COMPACTplus Application Examples | 10/2007

Control of Partial Muting Zones on Run-Time by 2 Sensors (3/6) Solution:  Static partial muting can be implemented by beam signal and muting enable input  Dynamic partial muting as required is basically not implemented in CPR-m -> additional means have to be used  The required sensor logic is: high-side sensor 1 high-side sensor 2 Beam Signal

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A: 1 = big object detected correctly

1

B: 1 = big object or person detected

If line A is 1, the state of B doesn’t matter to keep C at 1 If line A is 0, line B must also be 0 to keep C at 1

Leuze electronic | COMPACTplus Application Examples | 10/2007

C: Muting enable

Control of Partial Muting Zones on Run-Time by 2 Sensors (4/6) Solution:  AND logic between the 2 sensor inputs is realized by “Indication signal combination” using ORed dark switching and ORed light switching outputs of PRK light barriers  For HRT use inverse logic  Simultaneousness can not be monitored in this way !!  Signal A at output M4 is 1 if both sensors have switched correctly the dark switching output ON (i.e. L3=1) and the light switching output to OFF (i.e. L4=0)  In case of a sensor output or detection failure, output M4 is 0 dark switching output light switching output L3

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A: big object detected correctly -> M4

L4

M4 = L3 AND NOT L4 Connection of PRK high side sensors

Leuze electronic | COMPACTplus Application Examples | 10/2007

Control of Partial Muting Zones on Run-Time by 2 Sensors (5/6) Solution:  AND logic between the 2 sensor inputs is realized in “Indication signal combination” using dark switching and light switching outputs of the light barriers  OR logic is realized by 2 diodes in the end cap  M2 is used as “Muting enable” input of the “Muting” function  M3 and M4 are set to “Output”, i.e. state is read back safely and linked with OSSD Verify how “Output” works with the demo set by setting L2 as “Output”, bringing for example “Protective field free” at L2-Out, leaving the switch L2 at 1 and interrupting the protective field

L3 L4

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M4

“Indication signal combination” Beam Signal 1

M3

end cap

“Indication signal output” Muting enable

Leuze electronic | COMPACTplus Application Examples | 10/2007

M2

Control of Partial Muting Zones on Run-Time by 2 Sensors (6/6) SafetyLab Settings:  Basic I/O Configuration: 2-Sensor Parallel Muting

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Control and indication signals: M3, M4 = Output (i.e. read back and linked with OSSD)

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Muting: Muting enable signal: M2-In (connected in end cap by diodes to M3-Out and M4-Out)

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Protective field editor: set the high-load part to Beam Signal 1

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Indication signal output: Function = Inverted Input Input = Beam Signal 1 Output = M3

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Indication signal combination: Logic combination = AND Output = M4 L3-In = Direct, static L4-In = Inverted, static;

Leuze electronic | COMPACTplus Application Examples | 10/2007

CPSET-M20 (planned)

25 12, le M

TM CPR

ab ce c a f r nte ne I

m

Leuze electronic

Leuze electronic

CPSET-M20 consisting of:  CPRT500/2-m/T4 Muting Transceiver with M12 connector  CPM500/2V deflection mirror 

1 x PRK46B/66-S12 and 1 x TKS50x50 including fixing for nut

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Operator acknowledgement box with reset button and LED muting indicator with mounting plate for fence fixing

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Splitter cable for connection of light barrier and operator box

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M12 interface cable 25m

Parametering:  2-sensor muting with one PLC control signal and one light barrier signal within 4 seconds  With restart interlock and muting restart, without EDM 

Premature muting end on free protective field with filtering 1 second

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Increased MultiScan factor and sensor filter times

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Further changes ony possible with SafetyLab

Questions:  Machine Interface cable: length 25m or 15m? 

PRK46B or other series?

i ach

Leuze electronic | COMPACTplus Application Examples | 10/2007

Thank you for your interest in Leuze electronic products

Leuze electronic | COMPACTplus Application Examples | 10/2007