How to lower your machine safety cost with “Simply easy ... · implement “Simply easy” installation processes which cut overall safety system cost and – at the same time -

Simply easy!

How to lower your machine safety cost with “Simply easy!” installation processesChristophe GuichardDarren Smith

The innovative new contactless RFID Safety Sensor from Telemecanique Sensors is an example of a sensor solution that eliminates the pairing procedure [Figure 1]. The transponder and reader of the Telemecanique Sensors RFID safety sensor, called the XCSR, are paired at the factory using a unique, high-level coding. The sensor comes to the customer as a “plug and play” product, ready to install and virtually impervious to tampering.

Once all the necessary sensors are installed, the next step is to connect the installed sensors together into a sensor network. Once again, a “Simply easy” installation process will reduce the time and expense typically involved.

Reduce necessary connectionsPart 1: Consolidating sensor signals

Most modern machine automation systems have safety sensors positioned throughout the application, ensuring that each area is safeguarded against potential accidents. Typically, the larger the machine application, the greater number of safety sensors will be installed.

Regardless of the number of installed sensors or the obstacles between them, the goal is a

single, efficient sensor network which consolidates all the detection signals generated by the individual sensors.

As a result, we take the timeto connect them.

All of them.

Throughout the entire plant.

We take on this task despite the number of connectors, additional hardware, and

testing that is necessary during this typically time-consuming installation process.

Easier installations = reduced parts and labor expenseAs automation systems become more sophisticated, so, too, have the products that support and make up those systems. While sensors were previously evaluated solely

on the reliability of their performance, the ease of their integration now plays a considerable role. Machine

automation designers not only want reliable sensors, but they want them to be as close to “plug and play” as possible to reduce downtime.

Even a quality sensor initially appearing to be cost effective can become an expensive, time-consuming

burden when the complicated installation process accompanying it is revealed. Sensor companies aware

of the disruptive and expensive nature of these installations will cause them to focus not only on the performance of their sensors, but on how to improve the efficiency with which they can be installed. The overall installation design associated with the safety sensor becomes almost as important as the detection quality and reliability of the sensor!

In the sections that follow, we will look at three ways to implement “Simply easy” installation processes which cut overall safety system cost and – at the same time - magnify the overall value of the sensors associated with them.

Eliminate the pairing of sensor transponders and readersThe first step in installing some safety sensor products can be properly configuring the sensors themselves. Many older sensor models require pairing the sensor transponder with its reader to ensure proper communication between the two parts. This step, while anticipated by seasoned automation engineers, is a good example of an antiquated installation process that can be eliminated.

Machine automation

designers not only

want parts that are

reliable, but they

want them to be as

close to “plug and

play” as possible to

reduce downtime.

1 2

Figure 1

Telemecanique Sensors XCSR RFID Safety Sensor, including factory paired transponder (a)

and receiver (b).

(a)Transponder

(b) Receiver

...the path to

optimum system

efficiency can

be littered with

intensive labor, the

purchase of many

additional hardware

components, and

the frequently

significant expenses

involved with both.

Needless to say, the path to eventual system efficiency can be littered with intensive labor, the purchase of many additional hardware components, and the frequently significant expenses involved with both.

Part 2: Complex detection connections

Pictured in Figure 2 is a diagram of a series connection example for just 3 sensors. The diagram displays all the typical parts necessary to set up the connections.

As the illustration shows, the set-up requires three safety sensors (labeled “G”), three M12 connectors (“F”), a loopback device (“E”), three T-Connectors (“C”), two 4- or 5-pin M12 connection cables (“D”), an M12 8-pin connecting cable (“B”), and a safety control unit (“A”). An increased number of connected sensors will correspondingly increase the number of connection components.

Will there be additional expense to purchase all these extra components?

Yes.

Will there be expense to configure and properly install all these components?

Certainly.

Is there a way to reduce this expense?

Due to very recent innovations….yes.

3 4

Figure 2Series

connection example for 3 sensors

A

C

C

C

F

F

F

G

G

G

A

B

C

D

E

F

G

Safety control unit

M12 connecting cable, 8-Pin

T-Connector

M12 connecting cable, 4- or 5-Pin

Loopback device

M12 connection cable, 8-Pin

Safety sensor

E

Part 3: Connect fewer parts

At least one global leader in the detection industry has addressed the pain that can be involved with complicated installation processes. The results are sensor solutions that not only provide the reliable detection the customer is seeking, but also provides those solutions in a manner that is easy for the customer to order and to implement.

The global leader in this type of customer-oriented detection solutions is Telemecanique Sensors and an example of a customer-focused detection product is (again) the new XCSR RFID safety sensor. One of the major benefits to the XCSR is the extremely simple way it can be ordered and installed in a series (or “daisy-chain”) configuration. Just as Figure 2 depicted, Figure 3 also depicts a series connection of just three sensors. The stark contrast between Figures 2 and 3 is evident.

The configuration in Figure 3 requires three safety sensors (labeled “A”), two M12 5-pin connector cables (“B”), one M12 5-pin connecting cable (“C:), one loopback device (“D”), and one end connector (“E”). The numbers of parts that need to be ordered and connected are significantly reduced. The space required to install the system is reduced. The reduced number of physical parts means the labor required to set up the XCSR configuration is significantly reduced.

In fact, comparing the components cost alone of the two configurations reveals that Figure 3’s cost is approximately one third less than the cost for the parts in Figure 2’s configuration.*

Less expense up front.

Less expense when it is time to perform the installation.

Less valuable space allotted to accommodate the installation.

Connecting the sensors to a simple safety relay is the final step and it is another area where cost savings can be realized.

*based on Nov. 2019 cost comparison between the Telemecanique Sensors XCSR sensor and a competitor model. Contact Telemecanique Sensors for details of this study.

The new

approach not

only saves the

customer on

the cost of the

sensor itself,

but also saves

them on the

component

expense and

installation time.

A

B

C

D

E

Safety sensors

M12 connector cable, 5-Pin

M12 connecting cable, 5-Pin

Loopback device

Safety control unit

C

B

B

A

A

A

D

D

D

E

B

Figure 3ContactlessXCSR RFID

Safety Sensor series

connection example for 3 sensors

“Through a

diagnostic module,

the XCSR Safety

Sensor identifies,

locates and displays

the status of doors

and the presence

of any errors

along the line.”

5 6

Figure 4XCSR

single wire connection

to HMI interface accessing pre-

loaded software

Implementing XCSRXCSR transponders rotate for easier, flexible installation (Figure 6) and the XCSR is available in Standalone (Figure 7), Series (Figure 8), or Single (Figure 9) configurations.

To find out more about these breakthrough sensors designed for efficient installation and detection, get in touch with the sensor experts that can apply them to your specific application.

For a local Telemecanique Sensors consultant, go to: www.tesensors.com and select “Sales Personnel’ from the “Service and Support” menu.

More information is available at: www.tesensors.com/XCSR

MODBUS

(Re)Start

K1 K2

HMI

PC

KM1 KM2

Start

K2K1

K2K1

K2K1

K1

K2

Start

K2K1

K1

K2

(Re)Start

K2K1

K1

K2

(Re)Start

Figure 9SINGLE

configuration

Figure 7STANDALONE configuration

Figure 8SERIES

configuration

Transponder with two possible orientations of the sensitive face

Figure 6

Reduce wiring to andtime setting up an interfaceAfter a network is set up between the installed sensors, the final step of the process is to set up an HMI (a Human-Machine-Interface) or a controller to monitor the network. While previous “daisy-chain” sensor configurations could require multiple wires to be routed to a programming interface, newer, more customer-centric configurations require as little as one wire, regardless of the number of attached sensors!

The Telemecanique Sensors XCSR RFID Safety Sensor already described is configured with this feature. Pictured in Figure 4 is an example of an XCSR daisy-chain network. The green line represents the single wire connection that routes to a diagnostic module. For the HMI or the controller, the sensor chain status information is directly available in the diagnostic module Modbus registers.

The most advantageous part of this process is that no additional software is needed for an HMI to display the status of each sensor on the installed network. Through a diagnostic module, the XCSR Safety Sensor identifies, locates and displays the status of doors and the presence of any errors along the line.

As with the previously described installation features, the Telemecanique Sensors XCSR is extremely close to the ideal “Plug and Play” safety sensor.

Less time to connect to the interface.

No additional cost for software or software configuration time.

For our complete selection of sensor solutions, visit www.tesensors.com

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Due to the constant evolution of standards and equipment, the specifications indicated in the text and images of this document can only be guaranteed after confirmation by our departments. Print: Schneider Electric Photos: Schneider Electric ©2019 Schneider Electric. All Rights Reserved. Schneider Electric and Telemecanique are trademarks and the property of Schneider Electric SE, its subsidiaries and affiliated companies. All other trademarks are the property of their respective owners.

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Christophe GuichardTelemecanique Sensors

Global Marketing Product Manager - Safety Sensors

Darren Smith

Telemecanique Sensors

Marketing / Creative Services Manager