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Describes the modularity and flexibility of the WAGO I/O systems allowing connectivity of sensors and actuators to PLCs and PCs via the major fieldbus systems, and concludes that a modular approach leads to a greater saving in installed costs, installation and commissioning times for factory automation projects.

Safety‐related fieldbus is now being employed in many varied applications. Developments in fieldbus technology and programmable systems, coupled with developments in International and European Standards have created the opportunity for widespread use. Performance, equipment availability, flexibility, diagnostics and reduced cost of ownership are the principal reasons for rapid growth in safety‐related networking. The use of programmable safety systems has fundamentally have changed the way in which safety is now being engineered in the manufacturing plant. New devices provide direct connectivity to safety‐related networks, increasing the scope and changing the architecture of safety systems far beyond conventional expectations. Technological developments, application and benefits of safety‐related networking in industrial automation systems are shown. Criteria for safety network selection are highlighted.

This paper sets out to highlight the problem associated with the development of fieldbus diagnostics in a multi‐vendor environment and to propose a solution based on diagnostic function blocks (FB).

The work focuses on the “master‐slave” communication model in a PROFIBUS fieldbus system, where three different vendor solutions are investigated.

Although the fieldbus standards specify the type and format of the diagnostics data, the extent, location and sequence of diagnostics data within a controller are entirely vendor‐dependent. The outcome from this work defines a framework for representing the diagnostics data in the context of a special function block.

This research work defines a novel unified framework for representing the fieldbus diagnostics data using FB for multi‐vendor solutions in a PROFIBUS environment.

A review of safety‐technology, applicable safety‐related standards and the impact on the use of robots in industrial environments.

Technological developments are presented in safety‐related control technology, including programmable safety controllers, configurable safety controllers, safety networking and robotic safety in human environments. The technological developments are related to new and emerging safety standards.

The development of safety‐related technology and new international and European standards have fundamentally changed the way in which safety is now being engineered in industry. The introduction of new standards and revision of others have allowed safety‐related systems to utilise “state of the art” electronic, programmable, and network based technologies. New international standards are likely to include collaborative working with humans in the robotic workspace. This is set to change how robots are utilised in manufacturing environments.

The review of applicable standards and technical developments: with examples from current research and new technologies, demonstrating engineering solutions that embody the principles of the new standards.

Availability, reliability, flexibility and comprehensive diagnostics are the most significant demands placed upon safety systems today. Increasing payloads, work ranges and cycle times of robotic processes necessitate a different approach to safety, particularly other than that offered by conventional safety relays and fencing. The development of fieldbus for safety‐related applications and new International and European Standards have fundamentally changed the manner in which safety is now being engineered in the plant. BMW are the first to directly integrate robotic safety functions using a safety‐related fieldbus.

One of the main benefits of the fieldbus technology is its significant reduction in wiring. This is because each process requires only one wire to be run to the main cable. Installation costs are further reduced because the fieldbus is a multi‐drop rather than a point‐to‐point system. (The multi‐drop network can offer a 5:1 reduction in field wiring expense.) A number of pneumatics manufacturers have already developed devices for various programmable logic controller (PLC) fieldbus protocols, in the form of control blocks mounted directly on to standard pneumatic valve manifolds. The next generation of modular valve manifolds has emerged too. These do not need wiring, because they are based on a virtually “plug‐and‐play” design and installation method. This means that with this modular design one simply selects the valve configuration needed for the process, plugs the modules together, and the manifold is ready to connect into a fieldbus network.

The universal sensor interface chip (USIC) represents a complete signal processing capability for data acquisition systems designed to support a wide range of sensor applications. Offers high performance with flexibility and requires only a small number of external components for many applications.

To develop a decision framework for the planning and development of a flexible manufacturing system (FMS).

A systematic weighted property index approach for FMS development decisions is developed to evaluate various design options. This methodology converts design property values of differing orders of magnitude into a unitless system where an overall evaluation of the options can be made.

Major design choices related to the implementation of an educational FMS are identified, and considerations affecting each choice are discussed. A methodology for the selection of the appropriate FMS is then developed and demonstrated.

Provides a useful framework for evaluating various options in FMS development and selecting an appropriate system for a given environment and situation.

Identifies the major design choices related to the implementation of an educational FMS, provides practical examples taken from the development of FMSs at Southwest Missouri State University and the University of Missouri‐Rolla, and presents a systematic methodology for FMS design decision making.