Safety technology with KeSafe
Safe automation system for robotics
Safety for machines, robots and man
We make safety technology for robots and machines invisible for you. KeSafe helps you to implement the different requirements for safety technology quickly and flexibly and guarantees the safe operation of machines and robots in accordance with current standards and regulations. Functional monitoring assistants reduce the need for interference with safety controls to emergency situations only. All this is ensured by our highly-integrated decentralized safety solution. Additionally, safer operation of machines gives series machine manufacturers more flexibility for planning their systems.
Your benefits at a glance
- freely programmable and scalable safety solution
- easily adjusted to machine options and versions
- safety based on abstracted, reusable and certified basic functions for logic, motion and robotics
- services to create a range of applications (human-machine interaction, cobots, …)
Convenient thanks to application tool
Wide range of safe machine options
Open and universal
for many kinematics types
Service and advice
Support for applications and start-up
Safety technology included
KeSafe is the solution for safety technology for robots and machines. It is offered in combination with the compact control and drive system KeDrive for Motion. The integrated safety board guarantees secure operation of machines and robots in accordance with current standards and regulations.
Safety applications are created easily and efficiently with the certified functional modules. Our integrated solution enables optimal co-operation of functional and secure applications (assistant systems).
The secure communication between the individual safety components takes place via FSoE (Fail Safe over EtherCAT). The secure data transfer to the superordinate or subordinate safety systems is supported by several interfaces:
FSoE master/slave via EtherCAT
PROFIsafe slave for F-Device via PROFINET
The freely programmable safety application can be created easily using the application tool KeStudio SafeEdit that is integrated into KeStudio. Additionally, the tool allows for easy diagnosis and validation of the safety application.
Available in three configuration levels
The functionalities of our safety technology KeSafe covers simple logical links and secure single-axle functions as well as extended safety functions for robotics applications.
Secure logic applications
Pre-constructed components are used to build standard safety elements such as emergency stop switches, enabling switches etc. and are combined to create a complete safety application. Selectable logic modules allow for creating fully customized KeStudio links between input statuses and actuators can be targeted securely using secured digital outputs.
Driver-specific safety functions such as STO (Safe Torque Off) and SBC (Safe Brake Control) are realized in the same way.
- Certified functional modules for easy integration of common safety elements
- Freely programmable by linking secure input modules with secure output modules using standard logic modules
- Secure onboard I/Os and additional secure I/O modules can be controlled in a decentralized form via the FSoE master
Secure single-axle applications
Secure functionalities for single-axle monitoring can be realized with the KeSafe safety controls. KeStudio offers an individual module for each safety function that can then be integrated into the safety application. This allows for the representation of any safe machine functionalities on single axle basis.
- Manifold certified safety functionalities to monitor single axles in accordance with EN 61800-5-2
- No limits of combinations of KeSafe PLC functionalities
- Requirement: KeDrive encoder box and drive units with secure Hiperface-DSL encoders
Secure robotics applications
KeSafe Robotics offers extended safety functions for robotics applications. They enable you to realize your products/facilities in accordance with the safety requirements for industrial robots pursuant to EN ISO 10218. KeSafe Robotics modules are available for safety applications via KeStudio.
- Extended safety functionalities for robotics applications
- Can be used for any series kinematics
- Can be combined with KeSafe PLC and KeSafe Motion functionalities
- Requirement: KeDrive encoder box and drive units with secure Hiperface-DSL encoders
Perfect match for safety and robotics
A key concept for KeSafe is “invisible operation”. Security management should be invisible during normal production and should interact with the robotics control without being detectable for the user. KeSafe is like an observer who continuously checks calculations, recognizes danger and acts without interrupting the manufacturing process unnecessarily.
Safety technology with KeSafe at a glance
Four customized solutions
You can create holistic and secure robotics and machine applications with the following four hardware and software products. No additional safety assessment efforts are required.
Our engineering tool allows for simple and free programming of all safety applications using virtual links between the modules. Additionally, they include extensive diagnosis functions and support you in validating the safety application. You can create the maximum configuration for each machine option from the office and then adjust them easily to the machine on the production floor later.
Graphics editor for safety application (virtual links)
Supports all functional KeSafe configuration levels (thanks to extensive technology modules)
Freely programmable: extensive diagnosis options and support in validation
Version management (machine options)
KeDrive D3 with Safety Controller
The safety control combines safety logic and drive monitoring in a single device. Offers error-proof (onboard) inputs and outputs. This makes additional safety features for driver units unnecessary, with the exception of STO.
Simple safety functions to extended safety-based robotics solutions can be implemented without hassle.
Product features of KeDrive D3-DU 3x5
Best performance for I/O, single-axle and robotics safety
Quick reaction times
Highly integrated into functional controls
Can be expanded using secure bus protocols
Safety encoder box
The certified encoder box accepts decentralized inputs of encoder signals as well as additional secure inputs and outputs, which are sent to the control unit via a cable. The inputs make it possible to connect secure switches, buttons or other control elements directly to the machine or in the vicinity of the robot. All outputs are used for the secure control of engine breaks or are kept available for discretionary use.
In order to safely disengage the brakes (also without control cabinet), the safety functions are integrated directly into the encoder box - for example in order to prepare robots for transport or to monitor the speed (SLS) of disengaged axles.
Decentralized encoder analysis
Reduction of wiring
Fast dynamics monitoring
Secure drive unit
KeDrive DMS2 Motor with Safety Encoder
KeDrive DMS2 driver units are available with the high-resolution hyperface DSL encoders. Thanks to modern digital safety encoders, secure high-performance applications can be realized in a cost-efficient and time-saving one-cable method.
Highest degree of reliability
High overload capacity
Low torque ripple
One cable for performance and encoder signal
Many years ago now, the automation expert from Austria investigated how applications in human-robot interactions could be expanded profitably, without a considerable need for programming.
We have systematically advanced the KEBA robot core with abstracted, reusable basic functions.
Secure co-operation with KEBA’s scalable safety solution KeSafe is already available for all human-robot interaction applications subject to ISO TS 15066. The KEBA safety system for robots is not limited to any certain set of robot mechanics. KeSafe is open and universal by design. It provides functions such as secure cells, safe Cartesian speeds and secure monitoring of tools for a vast variety of freely configurable robot types. Special features: Not only robots and their tools can be represented in the safety controls, but also additional axles moving the robot itself or with which the robot cooperates.
Read more in the following article:
- Complete solution up to category 4, PLe under EN ISO 13849-1 or SIL3 under EN 62061 and EN 61508
- Safe single-axle function under EN 61800-5-2
- Safe robotics modules under EN ISO 10218
- Certificate: EC type examination certificate 01/205/5688.01/19
- Interface with superordinate safety devices and slave devices
- Safe onboard I/Os: safe digital inputs - 20 | safe digital outputs 2A - 2 | safe digital outputs 0,5A - 8 | safe relay exists - 2
Please contact us directly via email at [email protected].
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