How Schmersal’s Connectivity Solutions Drive Productivity and Advanced Error Diagnosis
In modern automation, the shift toward integration and networking is no longer optional—it is the foundation of the digital factory. The Schmersal Group is at the forefront of this trend, moving beyond traditional series and parallel wiring to offer sophisticated safety-oriented networking. These innovations allow manufacturers and users to reap the benefits of digitisation, including increased productivity, flexible system adaptation, and superior error diagnosis.
For decades, designers were limited in how they integrated safety switchgear. Today, a wide selection of fail-safe bus systems, safety fieldboxes, and diagnostic gateways provides a "lean" approach to machine safety circuits.
series via SD 4.0
Tried and Tested: The Power of the Safety Bus
The AS-Interface Safety at Work (ASi SaW) remains a cornerstone of efficient machine safety. By transmitting both operational and safety signals through a single yellow ASi flat-ribbon cable, Schmersal helps manufacturers reduce installation effort while providing operating companies with comprehensive evaluation data.
Benefits of AS-i Safety Systems
Minimal Wiring: Rapid installation using flat-ribbon cables.
Maximum Flexibility: Easy system modifications to meet evolving safety requirements.
Rapid Diagnosis: Quick identification of faults in complex, extensive systems to reduce downtime.
Continuous Communication from Switchgear to Higher Levels
Schmersal’s SD bus (Serial Diagnosis) has evolved into the SD 4.0 incarnation, designed for the capture of switching cycles and limit value warnings. This data is transmitted to an SD gateway or the Protect PSC 1 safety controller, enabling seamless communication up to OPC UA standards.
The New SD Fieldbus Gateway
A standout innovation is the SDF Fieldbus Gateway, which features an integrated web server and microSD card. This allows users to:
Evaluate event logs live via a web interface.
Read diagnostic data in plain text directly in a browser.
Control devices like solenoid interlocks and control panels remotely.
Safety Fieldbox: One System, Multiple Protocols
The Safety Fieldbox system allows for the plug-and-play connection of up to eight different safety switchgear devices—such as sensors, light curtains, and emergency stops—into a single field unit. This significantly reduces hardware costs and wiring complexity.
To ensure global compatibility, Schmersal has expanded its fieldbox range to support the world’s most common protocols:
PROFINET / PROFIsafe: The standard for the European market.
EtherNet/IP-CIP Safety: Widely used in North American and international markets.
EtherCAT FSoE: The newest addition, ensuring high-speed safety communication.
Sustainable and Future-Ready Connectivity
The transition to these networking concepts isn't just about efficiency; it's about resource management. By requiring significantly fewer cables, these systems reduce the consumption of plastic and copper, aligning industrial growth with environmental responsibility.
As we look toward the future, the "digital twin" and digital type plates will become standard. Connectivity will allow machine documentation to be retrieved instantly via M2M interfaces, making machine servicing more transparent and effective than ever before.
FAQ
What is AS-Interface Safety at Work (ASi SaW)?
It is a safety bus system that allows for the transmission of safety and operational signals over a single flat-ribbon cable, simplifying installation.
How does the Schmersal SD Bus improve maintenance?
The SD Bus provides serial diagnosis (SD 4.0) that enables predictive maintenance by identifying irregularities, like misaligned guard doors, before they cause downtime.
Which protocols does the Schmersal Safety Fieldbox support?
The Safety Fieldbox is compatible with PROFINET/PROFIsafe, EtherNet/IP-CIP Safety, and EtherCAT FSoE.
Why is reduced wiring important for sustainability?
Fewer cables mean a significant reduction in the use of raw materials like copper and plastic, making the manufacturing process more eco-friendly.
