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Seamless safety for production lines

Industry 4.0 demands modular, flexible production lines. While these qualities are being implemented successfully at a functional control level, achieving a comparable degree of flexibility in line-level safety technology has so far seemed an insurmountable hurdle. B&R aims to change that by combining OPC UA and openSAFETY to form Safe Line Automation – providing seamless safety for integrated production lines.


"In theory it is certainly possible to join machines from different vendors in a single safety network," explains Franz Kaufleitner, product manager for integrated safety at B&R, "but doing so requires an extensive amount of factory-floor programming." Once the line is up and running, any time you add, remove or modify equipment, you would need to reprogram and recheck the safety application. "That's just not a viable solution in real-world conditions," says Kaufleitner.

High level of flexibility required

That's why B&R is working on a concept that will open up a whole new realm of solutions: self-organizing safety networks based on OPC UA and the open source safety protocol openSAFETY. This technology will make it possible to add or remove entire machines or individual components from the machine network without having to reprogram the safety application. "It would even be conceivable to create a self-validating line," says Kaufleitner.

To allow the safety network to self-organize – while continuing to meet all the requirements for safety and security – there are a number of measures that need to be implemented. "This is where the particular advantages of OPC UA and openSAFETY really come to bear."

How it works

When a new piece of equipment – an entire machine, individual part or even a robot – is added to the machine network, OPC UA security mechanisms begin by establishing a secure connection.

The new device then searches for other servers that offer safety functions using the OPC UA discovery service and server capability identifiers, which allow servers on the network to be filtered according to desired criteria. In this way, any OPC UA server is able to obtain a complete map of the network without requiring a single line of code to be written. "This process can already be implemented using OPC UA," notes Kaufleitner.

Automatic validation

Next, the safety application checks whether the new component is already known, or if – with regard to safety – it matches a previously validated configuration. If so, there is nothing else for the machine operator to do.

If significant differences are identified, the user is asked to confirm via the HMI application whether the new configuration is correct. This input is saved, so the next time the same configuration will be recognized automatically.

Response time testing

"This is where openSAFETY comes into play," explains Kaufleitner. Each component checks the plausibility of the configuration. "This process is the same as the checks that are generally performed when a machine is started up." It includes a test of whether the response times and cycle times are fast enough to ensure reliable execution of the respective safety functions. Once these checks have been completed, exchange of safety-relevant process data via openSAFETY begins and the production line can resume operation.

Devices react automatically

As a minimum requirement for implementing safe line automation, each device needs to support openSAFETY's emergency stop profile. If an emergency stop button is pressed, all devices in the openSAFETY network are notified automatically. Each of them decides independently whether to enter an emergency stop state or if it's possible to continue running. "This would be the case, for instance, if the event affected a different emergency stop zone."

A linear profile is currently in development that will allow individual components of the machine or line to communicate directly with their neighbors. If one machine component enters a safe state, its immediate neighbors decide autonomously whether they need to enter a safe state as well, or if they are able to continue running, possibly at reduced speed. "All the components, throughout the entire line, communicate with each other without any intervention from a higher-level system or operator," says Kaufleitner.

openSAFETY meets OPC UA - full graphic - DE
Safe Line Automation combines OPC UA and openSAFETY to provide seamless safety throughout integrated production lines.

openSAFETY meets OPC UA - Layers - DE
openSAFETY exchanges data using the OPC UA publish-subscribe model.

How does openSAFETY communicate via OPC UA?

The open source safety protocol openSAFETY can use any fieldbus or Industrial Ethernet network as its transport medium. The black channel principle allows safety-relevant data to be exchanged without allowing it to be influenced by the transport protocol.

openSAFETY exchanges process data – in the form of Safety Process Data Objects – using the OPC UA publish-subscribe model. As a result, openSAFETY nodes can communicate with each other directly and achieve extremely fast response times. During the plausibility check, on the other hand, data is queried using Safety Service Data Objects. These make use of OPC UA method calling to avoid unnecessary traffic on the networks and OPC UA servers.

Download article as PDF:

Seamless safety for production lines.pdf


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Bernecker and Rainer Automatización Industrial S.L.U.
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