Integrated Functional Safety (FS)
Application
The safety concept of integrated functional safety (FS) for machines with HEIDENHAIN controls offers supplementary software safety functions in addition to the mechanical safety features of the machine. For example, the integrated safety concept automatically reduces the feed rate when you perform operations with open guard doors. The machine manufacturer can modify or expand the FS safety concept.
Requirements
- On controls with SIK1:
- Integrated functional safety (FS, basic version; software option 160) or Integrated functional safety (FS, full version; software option 161)
- Software options 162 to 166 or software option 169, if necessary
Whether you need these software options depends on the machine's number of drives.
- On controls with SIK2:
- Software option FS, basic version (#6-30-1)
- Software option FS, Safe axes (#6-30-2), if applicable
If your control is equipped with SIK2, software option #6-30-1 will enable four safe axes. You can order software option #6-30-2* multiple times and thus enable up to six additional safe axes.
- The machine manufacturer must adapt the FS safety concept to the machine.
Description of function
Every machine tool user is exposed to certain risks. While protective devices can prevent access to dangerous locations, the user must also be able to work on the machine without this protection (e.g., guard door opened).
Safety functions
To ensure that the requirements for operator protection are met, integrated functional safety (FS) provides standardized safety functions. The machine manufacturer uses the standardized safety functions for implementing functional safety (FS) for the machine in question.
You can track the active safety functions in the axis status of functional safety (FS).
Description | Meaning | Short description |
---|---|---|
SS0, SS1, SS1D, SS1F, SS2 | Safe Stop | Safe stopping of drives using different methods |
STO | Safe Torque Off | The power supply to the motor is interrupted. Provides protection against unexpected start of the drives |
SOS | Safe Operating Stop | Safe operating stop. Provides protection against unexpected start of the drives |
SLS | Safely Limited Speed | Safely limited speed. Prevents the drives from exceeding the specified speed limits when the protective door is opened |
SLP | Safely Limited Position | Safely limited position. Monitors safe axes to keep them within the limit values of a defined area |
SBC | Safe Brake Control | Dual-channel control of the motor holding brakes |
Safety-related operating modes of functional safety (FS)
Functional safety (FS) of a control offers various safety-related operating modes. The safety-related operating mode with the lowest number has the highest safety level.
Depending on how the machine manufacturer implements them, the following safety-related operating modes are available:
Refer to your machine manual.
The machine manufacturer must adapt the safety-related operating modes to each machine.
Icon | Safety-related operating mode | Short description |
---|---|---|
Operating mode SOM_1 | Safe operating mode 1: Automatic mode, production mode | |
Operating mode SOM_2 | Safe operating mode 2: Setup mode | |
Operating mode SOM_3 | Safe operating mode 3: Manual intervention; only for qualified users | |
Operating mode SOM_4 This function must be enabled and adapted by the machine manufacturer. | Safe operating mode 4: Advanced manual intervention, process monitoring, only for qualified users |
Functional safety FS in the Positions workspace
On a control with functional safety (FS), the monitored operating states of the speed S and feed rate F are displayed in the Positions workspace. If a safety function is triggered while in a monitored state, the control stops the feed movement and the spindle or reduces the speed (e.g., if a guard door is opened).
The Functional safety application
Refer to your machine manual.
The machine manufacturer configures the safety functions in this application.
In the Functional safety application in the Home operating mode, the control provides information about the status of the individual safety functions. In this application you can see whether individual safety functions are active and have been accepted by the control.
The Axis status menu item
In the Axis status menu item of the Settings application, the control provides the following information about the status of the individual axes:
Field | Meaning |
---|---|
Axis | Configured axes of the machine |
State | Active safety function |
Stop | Stop reaction |
SLS2 | Maximum speed or feed-rate values for SLS in the SOM_2 operating mode |
SLS3 | Maximum speed or feed-rate values for SLS in the SOM_3 operating mode |
SLS4 | Maximum speed or feed-rate values for SLS in the SOM_4 operating mode This function must be enabled and adapted by the machine manufacturer. |
Vmax_act | Currently valid speed or feed-rate limit If values are greater than 999 999, the control displays MAX. |
Test status of the axes
In order for the control to ensure safe operation of the axes, it checks all monitored axes when the machine is switched on.
The control checks whether the position of an axis matches the position directly after shutdown. If a deviation is detected, the control marks the respective axis in the position display with a red warning triangle.
If checking of individual axes fails when starting the machine, you can check the axes manually.
Checking axis positions manually
The control indicates the test status of the individual axes with the following icons:
Icon | Meaning |
---|---|
The axis has been tested or does not need to be tested. | |
The axis has not been tested, but must be tested to ensure safe operation. | |
The axis is not monitored by functional safety (FS) or is not configured as a safe axis. The axis is monitored by functional safety (FS), but the SLP safety function is deactivated. In machine parameter safeAbsPosition (no. 403130), the machine manufacturer defines whether the SLP safety function is activated for an axis. |
Feed-rate limiting with functional safety (FS)
Refer to your machine manual.
This function must be adapted by your machine manufacturer.
With the F limited toggle switch you can prevent the SS1 reaction for safe stopping of drives when the guard door is opened.
With the F limited toggle switch the control limits the speed of the axes and rotational speed of the spindle to the values defined by the machine manufacturer. The limitation depends on the active safety-related SOM_x operating mode. You can select the safety-related operating mode with the keylock switch.
In the safety-related operating mode SOM_1, the control stops the axes and spindles when the guard door is opened.
In the Positions and Status workspaces, the feed rate is displayed in orange.
Checking axis positions manually
Refer to your machine manual.
This function must be adapted by your machine manufacturer.
The machine manufacturer defines the test position.
To check the position of an axis: | ||
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- If necessary, move to a safe position before approaching the test positions
- Watch out for possible collisions
Notes
Machine tools with HEIDENHAIN controls may be equipped with integrated functional safety (FS) or with external safety. This chapter refers exclusively to machines with integrated functional safety (FS).