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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.

Recently there has been considerable technological change in the way in which safety‐related control may be engineered. A series of standards based upon IEC 61508 are under development. This paper discusses these changes and highlights their relevancy to machine safety.

An overview of technological change is given; from safety relays, to programmable safety controllers, safety‐related networks and the trend to combine safety and control functions in controllers and networks. Topics to consider when choosing between technologies are put forward, followed by a review of standards that incorporate functional safety.

The development of safety‐related standards, such as IEC 61508 provides general guidance on the design of safety‐related systems across a wide range of industries, with specific machinery implementation of the same principles in IEC 62061. There is overlap between IEC 62061 and ISO 13849‐1. The same functional safety principles are also implemented in IEC 61800‐5‐2 for adjustable power drive systems. IEC 61784‐3 embodies the functional safety concept in specific network technologies. Significant opportunities arise from the combination of technology and standards development to facilitate design, engineering and cost improvements.

Confusion is apparent in the application of emerging safety standards, coupled with dramatic changes in the approach to safety engineering. Areas of overlap between developing standards are highlighted, along with draft amendments intended to reduce potential conflict and perplexity. Incorporating functional safety into automation and industrial networking technologies enables engineers to produce innovative solutions that can lead to further improvements in machine safety, functionality, productivity and afford design, commissioning and maintenance benefits. Similar benefits are unlikely to be achievable with traditional safety technologies.

Areas of overlap between developing standards are highlighted, with amendments intended to reduce confusion in the intended audience. This paper seeks to raise awareness in the methods and benefits of incorporating functional safety into automation and industrial networking technologies.

This paper aims to propose a model for the provision of EtherNet/IP device‐specific function blocks by discrete industry device vendors and to outline how multi‐vendor network environments can benefit from the use of function block programming to encapsulate code for configuring communication, diagnostics and visualisation tools.

The approach makes use of function blocks to facilitate simpler use of the EtherNet/IP protocol. The EtherNet/IP messaging mechanisms are described, along with the methodology for configuring communication for both time‐critical and non‐time‐critical messaging, including device‐specific status and diagnostic data. The same approach is utilised for communication to visualisation systems.

Validation of the model was found to make data transfer between controller and device easier and faster, owing to a reduction in the number of operations a programmer was required to implement. Implementation time was found to be just 6.25 per cent of that needed to achieve the same functionality without the use of function blocks.

The use of function blocks to describe EtherNet/IP communication was tested with a commercial product in an application environment, and subsequently adopted by multiple vendors. A reduction in technical support was noted owing to the use of identical interfaces for multiple device instances. With complete device functionality described and readily available to the end‐user, greater device functionality is utilised and more often may otherwise not have been implemented for time, cost, or complexity reasons.

In the discrete industry, it is uncommon for device vendors to provide device‐specific function blocks describing network communication interfaces and functionality, since they reside in the controller, not the device. This research presents a novel method that provides a consistent, yet flexible approach for the configuration of EtherNet/IP communication for differing devices from multiple vendors within a controller.

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.

The ability of portable inspection arms for inspection and redesign of body in white assembly tooling is evaluated. Issues of data exchange between the systems used including the accuracy and usability of the data are discussed. Data generated are used to directly produce modified location blocks using selective laser sintering. This offers a rapid route for tooling modifications and has proved to be a robust solution despite initial doubts. Other uses of inspection arms are also discussed.

Wireless technology continues to evolve for the industrial market; however, there are several issues and challenges that must be addressed to ensure successful implementation. This paper discusses the development of wireless technology and standards and those that are currently applicable to industrial applications. Key considerations for successful implementation of industrial wireless Ethernet are presented, along with potential applications.

An overview of wireless applications is given. Wireless technology development is discussed, along with pertinent characteristics. The use standard Ethernet with automation protocols and their use with wireless is examined. Topics to consider when implementing wireless Ethernet in industrial applications are illustrated.

There are numerous diverse potential application areas for wireless, these include sensing, information, control and safety‐based applications with advantages derived from mobility, cable replacement and tracking opportunities. Each has differing characteristics. Considerations such as information or control use, and the challenges of interference, coverage, compatibility, safety, security and cost need be addressed to ensure a successful implementation. Use of commercial‐off‐the‐shelf (COTS) wireless components with standard unmodified Ethernet and automation protocols is advantageous to maximise the developments taking place in the wider Wireless Local Area Network (WLAN) market.

It is important to understand where wireless is appropriate and where it is not. Currently, most applications are information related, however, limited control and safety‐related use is possible today with potential future growth. A fully wireless factory is not feasible yet, since there is still a requirement to provide significant power to many devices. Technology developments in wireless and associated technologies will broaden the scope of wireless utilisation in the future.

The development of wireless technology and standards, in particular, those applicable to industrial applications are reviewed. The factors influencing wireless implementation in industrial environments are presented to assist in successful implementation. The opportunity to use the combination of an automation protocol, unmodified Ethernet and COTS wireless provides potential cost benefits, flexibility, and innovative solutions, whilst providing performance and cost advantages found in the overall WLAN market.