38 n SAFETY November/December 2025 www.drivesncontrols.com vision and transfer it to the radar sensor. It is possible to monitor areas with smaller or larger angles, as well as narrow or wide straight lines. Radar sensors also monitor 3D zones – volumes. Flexible, adaptable fields of view can be used to define walkways more precisely, thus optimising the use of space in production facilities. With Pilz’s PSENradar, for example, this is made possible by the sensors’wide opening angle. The field of view is adjusted in 10degree increments. The angle can be reduced on one or both sides. Some safe radar systems can now use the Safety over EtherCat (FSoE) open safety protocol, speeding up data transfer significantly. Not only do you get quick reaction times to events, but data is also transferred faster via a single cable. As safety “kicks in” faster with short reaction times, machine operators are also protected more rapidly from machine dangers. The singlecable connection also means that the machine is ready for operation faster. However, the radar's safety controller must be able to analyse the sensor data, and act independently from higher-level controllers. Pilz’s PNOZmulti 2 configurable small controller can achieve this, combining monitoring of all of a radar application’s safety functions in one device, and establishing connections to safe FSoE slaves in a network. It evaluates the sensor data in the safe radar system and, in doing so, achieves the SIL 2 safety level needed for robot applications. Radar sensors can be integrated quickly because they are easy to incorporate into applications using EtherCat. Configurator tools allow the right protection zone to be defined for each sensor, depending on the size of the area to be monitored. This depends on the arrangement, installation height and inclination of the sensor. In addition to the protection zone, it is also possible to configure a warning zone. If a person violates the warning zone, this is signalled by an optical signal, for example, allowing operators to react more quickly. Although radar is still a relatively new technology in the industrial environment, it is already well accepted, and has been used successfully in many applications. Developments such as apps based on augmented reality help users to visualise zone monitoring, even during the engineering phase, thus simplifying implementation. Area guarding of plant and machinery should be user-friendly. This means that devices for safe zone monitoring must be located “out of the way” and capable of being used in any industrial environment. Because radar sensors measure three-dimensional spaces, users can mount them on walls or ceilings. The flexible, integrable radar technology ensures the safety of a monitored zone – and its productivity. n A close-up view of a radar sensor which protects a three-dimensional area, detecting any movements in the zone. TÜV SÜD certifies IO-Link Safety spec, paving way for products The testing organisation TÜV SÜD has certified the IO-Link Safety specification V1.1.4, laying the foundation for the widespread industrial use of this technologyneutral safety system. Certification by an independent testing agency marks the end of the development phase for IO-Link Safety and allows the introduction of commercial products. In a separate development, the IOLink community has published a Security Deployment Guideline to help users to evaluate and implement security measures for IO-Link. IO-Link Safety is the safety-related extension of the IO-Link industrial communications technology and designed to allow seamless integration into existing automation and safety structures. Unlike standard IO-Link, IO-Link Safety relies on third-party certification. Manufacturers will have to have their products tested at a recognised test centre to ensure the highest quality and safety standards. As the first officially designated IOLink Safety test centre, TÜV SÜD has already started to test IO-Link Safety masters and devices. The first certified products are expected to be available soon. The costs to develop functional safety are high. IO-Link Safety requires support for only a single, easily implementable communication standard. As IOLink Safety devices can be used without modification in automation systems worldwide, the IO-Link community expects IOLink Safety to establish itself rapidly, and for the market to grow quickly. The main aim of the newlypublished IO-Link Secure Deployment Guideline is to provide end-users with the knowledge and tools needed to assess and implement security measures for using IO-Link. The free document provides detailed instructions and best practices for the use of secure IO-Link systems. By following the guide, users can ensure that their IO-Link systems are secure and resilient to potential threats. A further guideline for designing and developing IO-Link products securely is being developed and is nearing completion. The IO-Link Secure Design and Development Guideline is aimed at manufacturers that design and develop IO-Link products. It offers a guide to understanding and integrating security measures into IO-Link products, and is expected to serve as an essential reference to ensure safety in new products. There are now more than 20,000 IO-Link-compatible products available and more than 500 manufacturers of products that support the technology. The open architecture integrates easily into all common PLC, DCS and IoT systems. The Secure Deployment Guideline is available for free in the download area on the IO-Link website (www.io-link.com/downloads). The IO-Link Community has reached a significant milestone in the further development of IO-Link Safety.
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