Mm Apr Twinsafe

Safety Architecture

┌─────────────────────────────────────────────────────────────────┐
│                    TwinSAFE Safety Loop                          │
├─────────────────────────────────────────────────────────────────┤
│                                                                  │
│  ┌──────────┐     ┌──────────┐     ┌──────────┐     ┌─────────┐ │
│  │ E-STOP   │────►│ EL1904   │────►│ EL6900   │────►│ EL2904  │ │
│  │ (Ch1+Ch2)│────►│ DI 1+2   │     │ Safety   │     │ DO 1-4  │ │
│  └──────────┘     └──────────┘     │ Logic    │     └────┬────┘ │
│                                    │          │          │      │
│  ┌──────────┐     ┌──────────┐     │          │          │      │
│  │ Light    │────►│ EL1904   │────►│          │          ▼      │
│  │ Curtain  │────►│ DI 3+4   │     │          │     ┌─────────┐ │
│  │ (OSSD)   │     └──────────┘     └──────────┘     │ E1 STO  │ │
│  └──────────┘                                       │ STO1/2  │ │
│                                                     └─────────┘ │
└─────────────────────────────────────────────────────────────────┘

EL1904 Input Configuration

Channel Assignment

Wiring Requirements

• Dual-channel wiring for E-STOP (redundancy)
• Light curtain OSSD: PNP, 24VDC
• Cable shield grounded at one end
• Max cable length: 100m

EL2904 Output Configuration

Channel Assignment

Wiring to E1 Drive

EL2904 DO1 ────────────► E1 Drive Axis A STO1
EL2904 DO2 ────────────► E1 Drive Axis A STO2

EL2904 DO3 ────────────► E1 Drive Axis B STO1
EL2904 DO4 ────────────► E1 Drive Axis B STO2

EL6900 Safety Program

Function Blocks

Safety Logic Example

PROGRAM SafetyPLC
VAR
    // Inputs from EL1904
    bEStop_Ch1      : BOOL;
    bEStop_Ch2      : BOOL;
    bLightCurtain1  : BOOL;
    bLightCurtain2  : BOOL;
    bResetButton    : BOOL;

    // Outputs to EL2904
    bSTO1_AxisA     : BOOL;
    bSTO2_AxisA     : BOOL;
    bSTO1_AxisB     : BOOL;
    bSTO2_AxisB     : BOOL;

    // Function Blocks
    fbEStop         : SF_EmergencyStop;
    fbLightCurtain  : SF_ESPE;
END_VAR

// E-STOP evaluation
fbEStop(
    Activate := TRUE,
    S_EStopIn := bEStop_Ch1 AND bEStop_Ch2,
    S_StartReset := bResetButton,
    S_AutoReset := FALSE,
    Reset := bResetButton
);

// Light curtain evaluation
fbLightCurtain(
    Activate := TRUE,
    S_OSSD1 := bLightCurtain1,
    S_OSSD2 := bLightCurtain2,
    S_StartReset := bResetButton,
    Reset := bResetButton
);

// Combined safety output
bSTO1_AxisA := fbEStop.S_EStopOut AND fbLightCurtain.S_ESPE_Out;
bSTO2_AxisA := bSTO1_AxisA;
bSTO1_AxisB := bSTO1_AxisA;
bSTO2_AxisB := bSTO1_AxisA;

Safety Response Times

Safety Functions

STO (Safe Torque Off)

• Removes torque from motor
• Does NOT control position
• Used for: E-STOP, light curtain intrusion

SS1 (Safe Stop 1)

• Controlled deceleration
• Then activates STO
• Used for: Graceful safety stop

SBC (Safe Brake Control)

• Controls mechanical brake
• Activates after STO
• Prevents gravity fall (vertical axes)

Safety Solution Architecture (4 Frameworks)

The APR safety system integrates components from multiple frameworks:

Framework Integration

1. Beckhoff TwinSAFE - Core safety PLC and I/O
2. HIWIN E1 STO - Drive-integrated safety
3. Keyence GL-V - Safety light curtain
4. ISO 13849 / IEC 62443 - Safety standards compliance

Safety Zones

┌─────────────────────────────────────────┐
│              Safety Zone A               │
│  ┌─────────────────────────────────┐    │
│  │        Light Curtain Zone       │    │
│  │   (GL-VM72HP, 1440mm height)    │    │
│  └─────────────────────────────────┘    │
│                                          │
│  ┌─────────────────────────────────┐    │
│  │       Motion Hazard Zone        │    │
│  │  (LMSA13L, 4.2m travel, 9.7m/s) │    │
│  └─────────────────────────────────┘    │
└─────────────────────────────────────────┘

Commissioning Checklist

• Verify EL1904 input wiring (dual-channel)
• Configure EL6900 safety program
• Link EL2904 outputs to E1 STO inputs
• Test E-STOP function (both channels)
• Test light curtain response
• Measure actual response time
• Verify reset button function
• Document safety validation

Safety Categories

TwinSAFE with EL1904/EL6900/EL2904 supports up to SIL 3 / PLe.

Available References

• references/framework-integration.md - ASCII blueprint integrating 4 safety frameworks
• references/github-hosting.md - APR_HiwinLMSA_SafetyGate GitHub hosting plan