Highly Scalable, Highly Modular: Safe Automation with TwinSAFE

A Winning Edge with Beckhoff Control

Beckhoff implements open automation systems on the basis of PC-based control technology, including safety. This approach offers:

• All functions on one platform
• High-performance control solution
• High-performance EtherCAT fieldbus
• Modular and scalable architecture

Beckhoff's comprehensive, highly scalable, and modular automation portfolio extends from IPCs to I/O, motion, and software. This allows seamless integration of all functionalities, from HMI to measurement technology, IoT, vision, PLC, and motion, through to safety. Machine builders benefit from a uniform tool base and hardware platform, enabling the integration of safety and non-safety functions, effectively ending the historical separation.

A Winning Edge with Beckhoff Safety

Beckhoff Safety provides:

• System-integrated safety functionality
• Free choice of architecture
• Comprehensive safety expertise
• Open communication

TwinSAFE offers ultimate flexibility and scalability, allowing safety features to be integrated into any machine architecture, from stand-alone to distributed and software-based control. Beckhoff's extensive safety expertise ensures tailored solutions, avoiding unnecessary costs. The principle of openness is key, with the Safety over EtherCAT (FSoE) protocol being internationally certified and allowing transmission via any media.

Benefits of Complete Integration:

• Consistency: Everything from one source.
• Connectivity: All information available in one integrated system.
• Adaptability: Modularity and scalability for current and future requirements.

Complete: The Right Solution in All Application Areas

TwinSAFE is a cross-sectional solution applicable across all automation areas. Beckhoff's non-safety automation technology is divided into IPC (control), I/O (input/output), motion (drive technology), and automation (software). As complexity grows, so do safety requirements. TwinSAFE offers appropriate solutions for all these areas.

Engineering: The TwinCAT Safety Editor and other tools enable intuitive and flexible creation of safety solutions. A certified application manual simplifies the engineering process from conceptual design to realization. Beckhoff's safety and non-safety tools are merged for universal configuration and programming.

Control: High-performance TwinSAFE safety controllers are available in various form factors to support every safety application.

I/Os: Safe input and output modules are available in various granularities for optimal adaptation to individual requirements, including EtherCAT Terminals, EtherCAT Box modules, and EtherCAT plug-in modules.

Motion: High-performance TwinSAFE components for motion control integrate safety functionalities into drive solutions, supporting safety technology drive functions.

Flexible Implementation:

• Comprehensive software support
• High-performance safety controllers in various form factors
• Safety components for different environmental conditions
• Safety components in diverse granularities for optimum adaptability

Safety-over-EtherCAT: Open for All

The Safety-over-EtherCAT (FSoE) protocol defines open, secure data transmission. Certified by TÜV, it is internationally standardized according to IEC 61784-3 and fulfills safety requirements up to SIL 3 (IEC 61508). FSoE treats the transport medium as a "black channel", meaning it can be transmitted over any communication technologies, including EtherCAT, Ethernet, standard fieldbus systems (like CAN), and wireless networks.

FSoE is an ideal complement to open EtherCAT technology, guaranteeing high-performance transmission of control and safety information via the same communication system.

Benefits of the Flexible Communication System:

• Flexibility through transmission via any media.
• Flexibility through a large number of component vendors.

TwinSAFE: Logic in All Components

The integration of TwinSAFE Logic functionality into new TwinSAFE components significantly extends deployment and application scenarios, offering greater flexibility. For example, integrated TwinSAFE Logic in a digital input component (e.g., EL1918) allows selective preprocessing of sensor data directly on the component. This preprocessing can be developed and validated separately, reducing the complexity of the centralized safety application and simplifying validation.

This integrated logic can also be used to control entire axis groups (e.g., within an AX8000 servo system) from a safety perspective, while a central controller manages the overall group.

Application Scenarios of Integrated Logic:

• Specific preprocessing of signals directly by input components.
• Fast local responses through localized safety applications.
• Efficient and flexible modularization without additional costs.

Individually Scalable: The TwinSAFE Architectures

TwinSAFE enables machine builders to realize diverse safety architectures with components in different form factors. This offers attractively priced, flexible, and optimally scalable solutions, ensuring compliance with safety requirements now and in the future.

Architectures include:

• Stand-alone Control

  Components can operate without connection to an EtherCAT master, allowing easy realization of limited local safety applications. Example: EK1960, EP1957-0022.

• Compact Control

  New TwinSAFE components with integrated Logic functionality can realize compact safety applications or input data preprocessing. Example: EK1960, EL2911, EL1957.

• Centralized Control

  The traditional architecture where a dedicated safety controller communicates with multiple participants, processing all safety-related data centrally. Example: EL6910, EL6900, EL6930.

• Distributed Control

  Allows modularization of safety applications, distributing the safety project across multiple logic-capable components. Functionally related components can be modeled by dedicated safety projects, with communication via user-specified interfaces. Example: EL1918, EL6910, EL2911, EL1957, EL2912, EJ series, AX8000.

• Software-based Control

  Utilizes the TwinCAT Safety PLC software as a central component, leveraging the performance of Industrial PCs for highly complex safety applications. This can be programmed using Safety C. Example: C6920, CX5120.

For Analog Safety Solutions: TwinSAFE SC

TwinSAFE SC (Single Channel) technology allows the use of standard signals for safety-relevant tasks across any networks or fieldbus systems. EtherCAT I/Os with functions like analog inputs (e.g., 4...20 mA) or encoder interfaces are extended with the TwinSAFE SC function, preserving their typical signal properties and standard functionalities. TwinSAFE SC I/Os are visually distinguished by a yellow stripe.

Data is routed via a TwinSAFE protocol to the TwinSAFE logic for safety-related applications. This enables economic use of standard signals and simple expansion of existing systems with safe analog value processing. Example: EL3124-0090, EL3314-0090, EL5021-0090, EP3174-0092.

Safety Engineering: Simple, Intuitive, and for Complex Applications

Beckhoff offers flexible programming options for safety applications:

• With Function Block Diagrams

  Safety applications can be programmed using a graphical editor in TwinCAT 3, utilizing certified safety function blocks for simple and intuitive implementation. This is suitable for basic functionalities like safety door monitoring or complex muting functions.

• With Safety C

  Highly complex safety applications can be programmed using Safety C, a derivative of Standard C, within the TwinCAT 3 environment. This allows free programming of complex logic, with optional restrictions for increased safety, such as strict type identification.

Flexible Programming Options:

• Selection of programming language depending on requirements.
• Intuitive programming for basic safety functionalities.
• Free programming in a high-level language for highly complex applications.

Simple Adaptation, High-Performance Tools: The Engineering Highlights

Beckhoff provides tools for flexible engineering and deployment:

• Customizing

  Allows safety technology subgroups to be configured, temporarily deactivated, or switched to passive mode during runtime. This enables ultimate flexibility in adapting machines to prevailing requirements. A single safety project can be used for multiple machine variants by deactivating unused modules, reducing development costs. Switching modes is possible during runtime.

• CAD Integration

  Safety application configuration can be done directly within CAD tools using the AML interchange format, converting it into a functional TwinCAT 3 project.

• TwinSAFE Loader/User

  TwinSAFE Loader: A command-line tool for downloading and customizing safety projects at runtime without needing the TwinCAT development environment. It simplifies commissioning and allows modules to be activated/deactivated without re-validation. It can be integrated into customer-specific processes.

  TwinSAFE User: A command-line tool for user rights administration regarding TwinSAFE Logic components.

Flexibility in Application and Tooling:

• Highly flexible modularization during runtime through customizing.
• Preconfiguration of safety applications within CAD tools.
• User-friendly tools (TwinSAFE Loader, TwinSAFE User) for series production.
• TwinSAFE Loader enables runtime modularization without TwinCAT 3.

At a Glance: The TwinSAFE Software Workflow

The TwinSAFE workflow covers the entire process from risk assessment to deployment:

1. Risk Assessment

   Determines the required performance level (PL) based on severity of injury (S1/S2), frequency/exposure (F1/F2), and possibility of avoiding hazard (P1/P2).

2. Specification

   Safety projects can be preconfigured in CAD tools using the TC3 XCAD Interface, which generates a functional TwinCAT 3 project. Alternatively, configuration can be done using Codesys Safety.

3. Development

   Safety applications are developed using the TwinCAT 3 Safety Editor, supporting Function Block Diagrams and Safety C.

4. Deployment

   Projects are deployed from TwinCAT 3 Engineering. The TwinSAFE Loader allows deployment and customization without the TwinCAT environment, useful for series production and runtime adjustments. The TwinSAFE User tool handles user management.

Flexible Workflow Support:

• Comprehensive support during the engineering process.
• Free choice of development tool.
• Various deployment possibilities for different requirements.

Simplified Implementation: The Application Manual

The TwinSAFE application manual, available for download, simplifies the design of safety functions. It contains a collection of sample applications and widely used safety functions, detailing hardware component interconnection and corresponding mapping within the safety application using pre-certified function blocks and parameterization.

Each sample includes verification of the safety level confirmed by TÜV SÜD, allowing direct adoption or simple adaptation to specific requirements.

Manual Content:

• Detailed description of every safety function, including parameterization.
• Block circuit diagrams and output parameters for each function.
• Transparent calculation of safety parameters for easy adjustment.
• Detailed description for determining the correct safety category.

Comprehensive Support:

• Continuously expanded collection of relevant application examples.
• Best-possible support for correct implementation of safety applications.
• Simple adaptation to modified applications through detailed documentation.

Highly Modular: The TwinSAFE Product Portfolio

TwinSAFE offers a comprehensive range of components:

Input, Logic and Output Modules

• EL2911: EtherCAT Terminal, 4-channel digital input, 1-channel digital output, 24 V DC, Imax = 10 A
• EL1957: EtherCAT Terminal, 8-channel digital input, 4-channel digital output, 24 V DC, Imax = 0.5 A
• EP1957: EtherCAT Box, 8-channel digital input, 4-channel digital output, 24 V DC, Imax = 0.5 A
• EJ1957: EtherCAT plug-in module, 8-channel digital input, 4-channel digital output, 24 V DC, Imax = 0.5 A
• EK1960: TwinSAFE Compact Controller, 20 safe inputs, 24 safe outputs, optionally 4 relay outputs
• AX81xx-0100: Drive with TwinSAFE option, 1 axis
• AX82xx-0100: Drive with TwinSAFE option, 2 axes

Input and Logic Modules

• EL1918: EtherCAT Terminal, 8-channel digital input, 24 V DC
• EP1918: EtherCAT Box, 8-channel digital input, 24 V DC
• EJ1914: EtherCAT plug-in module, 4-channel digital input, 24 V DC
• EJ1918: EtherCAT plug-in module, 4-channel digital input, 24 V DC

Input Modules

• EL1904: EtherCAT Terminal, 4-channel digital input, 24 V DC
• EK1914: EtherCAT Coupler with integrated digital standard and safety I/Os: 2 safe inputs, 2 safe outputs, 4 standard inputs, 4 standard outputs, Imax = 0.5 A
• EP1908-0002: EtherCAT Box, 8-channel digital input, 24 V DC
• KL1904: Bus Terminal, 4-channel digital input, 24 V DC

TwinSAFE SC (Selection)

• EL3124-0090: EtherCAT Terminal, 4-channel analog input, 4...20 mA, 16 bit
• EL3314-0090: EtherCAT Terminal, 4-channel input, thermocouple
• EL5021-0090: EtherCAT Terminal, 1-channel SinCos encoder interface
• EP3174-0092: EtherCAT Box, 4-channel analog input, ±10 V or 0/4...20 mA, 16 bit

Dedicated Logic (Engineering with FBD)

• EL6910: EtherCAT Terminal, TwinSAFE Logic
• EL6900: EtherCAT Terminal, TwinSAFE Logic
• EL6930: EtherCAT Terminal, TwinSAFE Logic, with PRO
• EJ6910: EtherCAT plug-in module, TwinSAFE Logic

Dedicated Logic (Engineering with Safety C)

• TwinCAT Safety PLC: Software-based safety controller

Logic and Output Modules

• EL2912: EtherCAT Terminal, 2-channel digital output, 24 V DC, Imax = 2.3 A
• EJ2914: EtherCAT plug-in module, 4-channel digital output, 24 V DC, Imax = 0.5 A
• EJ2918: EtherCAT plug-in module, 8-channel digital output, 24 V DC, Imax = 0.5 A
• KL6904: Bus Terminal, 4-channel digital output, 24 V DC, Imax = 0.5 A

Output Modules

• EL2904: EtherCAT Terminal, 4-channel digital output, 24 V DC, Imax = 0.5 A
• EK1914: EtherCAT Coupler with integrated digital standard and safety I/Os: 2 safe inputs, 2 safe outputs, 4 standard inputs, 4 standard outputs, Imax = 0.5 A
• KL2904: Bus Terminal, 4-channel digital output, 24 V DC, Imax = 0.5 A

Motion

• AX5000: Digital Compact Servo Drives
• AX5801-0200: TwinSAFE drive option card, up to 40 A, STO, SS1
• AX5805-0000: TwinSAFE drive option card, up to 40 A, STO, SS1, SS2, SOS, SLS, SDI
• AX5806-0000: TwinSAFE drive option card, up to 60 A, STO, SS1, SS2, SOS, SLS, SDI

Globally Available: Beckhoff Safety Expertise

Beckhoff Automation has a worldwide presence in 75 countries, ensuring fast service and support for globally operating customers in their local language. Geographical proximity helps Beckhoff understand the technical challenges faced by customers worldwide.

Beckhoff at a Glance:

• Headquarters in Verl, Germany.
• Global sales in 2021: 1.182 billion euros.
• Worldwide employees: 5000.
• Engineers: 1900.
• Subsidiaries/representative offices worldwide: 39.
• Branch offices in Germany: 24.
• Distributors worldwide: More than 75 (Status: March 2022).

Beckhoff's "New Automation Technology" philosophy represents innovative control and automation solutions used worldwide across various applications and industries.