Safety PLC facilitates fail-safe condition monitoring

ABB is launching what it claims is the world's first safety PLC with integrated condition monitoring. This will improve overall functional safety of various applications in compliance with international machinery safety standards and reduce the need for manual inspection and maintenance.

Fail-safe condition monitoring complements standard condition monitoring, enabling many more applications to feature functional safety on-board. This opens up the ability to, for example, safely monitor the brake status of automated guided vehicles, trains or mobile machines using measured vibration levels. Another application is the safe monitoring of excessive vibrations experienced by centrifuges or wind turbines.

For instance, precise measurement of vibration signals with a wide range of frequencies up to 20kHz can be safely supervised, thereby avoiding spontaneous critical failures like wind turbine or centrifuge collapse. Also, vibration-based monitoring of brakes, such as on mobile machines, enables longer intervals between inspections, as fail-safe supervision provides more precise data on the status of safety-critical machine parts.

Furthermore, fail-safe condition monitoring, together with predictive maintenance, provides an early warning that prevents machine breakdown and the costly consequences of stopping production. For example, safely-limited speed mode activation can be implemented to reduce downtimes based on feedback from the fail-safe condition monitoring instead of safe emergency stop, whenever it is permitted in the application.

Modular architecture

The system uses ABB's AC500-S Safety PLC, the modular architecture of which enables the combination of the PLC's fail-safe and condition monitoring units. Safety functions up to SIL CL 2 (IEC 62061), SIL2 (IEC 61511) and PL d (ISO 13849-1) can be implemented with fail-safe condition monitoring.

The expected analogue safety signal's profile can be saved within the safety PLC's 120kB flash memory. The measured signals connected to the AC500's condition monitoring module channels can then be compared with the predefined signal profile saved on the safety PLC. If the difference exceeds the permitted range, then the safety reaction is triggered.

Using SM560-S-FD-4 Safety CPU and CM589-PNIO-4 Profinet IO device ensures that the safe evaluation result can be exchanged from one fail-safe condition monitoring system to multiple safety controllers, including third-party, using Profinet/PROFIsafe. This enables implementation of the full machine emergency stop or plant-wide emergency stop function, whenever required.

Easy integration

In general, condition monitoring using ABB's AC500 PLC provides easy integration with all kinds of machinery systems, enabling precise management of an application's real-time condition. This provides more efficient machines, predictable performance and significant reductions in maintenance costs.

Whether condition monitoring is standalone or integrated into a machine or process control, the AC500 is suitable for building optimised, self-analysing automation systems that simultaneously perform condition monitoring, control, protection, safety and data logging functions with one controller.

Planned maintenance rather than spontaneous repair ensures predictable performance. Impending damage is identified and prevented very early. Costs in maintenance and lost production time are also reduced, and plant availability is increased. Optimum utilisation of the aggregates until real end of life is provided. It is simple to use, maintain, adapt or expand. For more information, go to www.abb.com/plc.

ABB Automation Technologies (Instrumentation & Automation)

Howard Road
Eaton Socon
St Neots
PE19 8EU
UNITED KINGDOM

+44 (0)1480 475 321

enquiries@gb.abb.com

www.abb.com

More from ABB Automation Technologies (Instrumentation & Automation)

Integrating electric motors into efficient smart factory systems

Posted 4 weeks ago

Greater protections for harsh and cleanroom applications

Posted 2 months ago

Ability to unlock multiple benefits revealed

Posted 6 months ago

ABB Robotics global launch

Posted 8 months ago

ABB supports the first Safe HMI with in-built Profinet/Profisafe

Posted 1 year ago

ABB control system raises productivity for cable manufacturer

Posted 2 years ago

Condition monitoring system helps company target zero downtime

Posted 2 years ago

Blockchain for traceability in food and beverage production

Posted 2 years ago

New PLC CPUs enable connection to the cloud

Posted 2 years ago

ABB appoints new Industry Network Leader for food and beverage

Posted 3 years ago

What eggs can teach us about traceability

Posted 3 years ago

Real-time exchange of high-volume data between PLC controllers

Posted 3 years ago

ABB earns Frost & Sullivan 2017"Ž Company of the Year Award

Posted 3 years ago

Economical and robust control panel provides efficient HMI

Posted 5 years ago

New ABB safety PLC ensures safety of crane operation

Posted 6 years ago

Advanced PLC addresses emerging challenges in machinery control

Posted 6 years ago

State-of-the-art safety upgrade for stainless steel rolling mill

Posted 7 years ago

New ABB AC500-XC PLC for operation in extreme conditions

Posted 8 years ago

Extended Automation System 800xA sells 4000+

Posted 13 years ago

ARC names ABB world leader in DCS market

Posted 14 years ago

FTIR spectrometer offers exceptional price/performance ratio

Posted 14 years ago

PAT system can save millions of dollars per year

Posted 14 years ago

GE Healthcare selects ABB automation system

Posted 14 years ago

ABB consultant qualifies as TUV Functional Safety Expert

Posted 14 years ago

Controller and recorder selection for food and beverage plant

Posted 14 years ago

Batch monitoring helps to prevent product recalls

Posted 14 years ago

New applications for electronic data recorders

Posted 14 years ago

Videographic data recorders now store batch data

Posted 14 years ago

ABB EOW workstation enhances customer support

Posted 14 years ago

ABB control system improves Corus blast furnace

Posted 14 years ago

More products

Login / Sign up