Define the responses
Assign the specified protective functions in a safety matrix.
A safety function has to
respond at the right moment
Implement specified protective functions in control software and test their response on the plant.
A correctly selected safety component does not yet prove the function of the entire protective chain. Parameterisation, assignment and software have to fit together so that the intended response can be tested.
IQstruct Engineering programs and tests safety-related control functions on the basis of the agreed safety requirements. The safety matrix, F-addresses, module assignment and checksums are taken into account, as is single-channel or dual-channel evaluation. For drives, agreed tests of functions such as STO and SLS are part of the scope.
Start now at no cost
In a free first conversation we clarify which safety functions the plant needs and which documents for the record of evidence are already available.
Scope of services
Program the safety
Integrate safe controllers and communication in the context of the plant.
Test the functions
Document responses and the agreed measurements at the plant.
Safety controllers and communication
Safety functions run on dedicated safety controllers or on fail-safe components of the automation platform.
We program PILZ PNOZ, Siemens F-CPUs with F-modules and safe inputs and outputs, as well as Beckhoff safety components. The programs cover safe states, releases, shutdowns, operating modes and the evaluation of protective devices.
PROFIsafe transmits safety-related information via PROFINET and PROFIBUS, Safety over EtherCAT does so in Beckhoff environments. Safety light curtains monitor access points, safety laser scanners monitor defined areas with warning and protective fields. Their design follows the application and the risk assessment.
Approach in the project
Ai1
Assign protective functions
The specified safety matrix connects protective devices, operating states and responses.
Ai2
Program the safety functions
Safety program, F-addresses and module assignments are implemented in the controller.
Ai3
Test the protective function
Each protective device is triggered while the hazardous movement runs; the stop and the overtravel are measured.
Ai4
Document the test
Test report and measurement results are assigned to the tested configuration.
Classification
Classifying SIL and performance level correctly
SIL in accordance with IEC 62061 and performance level in accordance with ISO 13849-1 describe the requirement placed on a safety function.
Which level is required results from the risk assessment and the defined safety functions. The characteristic values of individual components do not yet prove the level of the entire function; architecture, diagnostics, software and validation are part of it.
Frequently asked questions
We are glad to answer your detailed questions in a personal conversation.
Is a complete risk assessment included?
As a rule, IQstruct Engineering does not prepare a complete risk assessment. A required SIL or performance level is not promised across the board.
Can safety functions be tested on the model?
Safety functions are prepared and tested functionally on the simulation model. Measurements and validations on the assembled plant remain part of on-site commissioning.
How often do protective devices have to be tested?
The test cycle depends on the risk assessment, the manufacturer's information, the operating conditions and the applicable regulations. It is defined for the plant in question.
What applies to cobots?
A cobot may not automatically work without a separating protective device. Tool, forces, safe spaces and releases are considered for the entire robot application.
Protective functions
Every safety function is tested on the plant
Programming, parameterisation and the measured response are documented and assigned to the tested configuration.
Further industry solutions
Every industry has its particularities. That calls for a reliable partner who knows the requirements and delivers suitable solutions.
- Special purpose machineryEvery machine comes about once, and its control code comes about with it.
- Agricultural machineryMachines work spread across the field, and their data arrives with delay and with gaps.
- Woodworking and furnitureWood is a grown material, and its fault images are hard to describe as a fixed rule.
First conversation
Arrange a free first conversation
Describe your task. We agree a date and discuss the possible project scope.
Ai1
You request an appointment
Ai2
We discuss your requirements
Ai3
You receive a quotation for the agreed scope
Tobias KuckBusiness Development ManagerTakes up new projects, coordinates offers and accompanies the cooperation from the first enquiry.
Free first conversation
Describe your task in the contact form. We come back with a proposed date.
Arrange a first conversationBooking calendar
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Not quite what you need?
Discover further suitable services.
PLC programming, HMI and SCADA
Connect sequence control, operation and diagnostics in one coordinated automation concept.
Robot programming
Prepare movements and interfaces offline and fine-tune them on the real cell.
On-site commissioning
We bring software, peripherals and real sequences together, from the I/O check to the ramp-up.