Compatibility between new robotic systems and existing processes is crucial

By Staff Report March 1, 2025 11:27 am IST

Factories are embracing digitisation, which raises industrial security risks and demands robust safety solutions. In this interview, we discuss how Pilz ensures machinery safety, industrial security, and seamless robotic integration while addressing challenges and compliance with evolving safety standards for efficient manufacturing operations.

Why has the risk of industrial security increased with the digitisation of factories?

Industrial security safeguards production and industrial plants from intentional and unintentional faults. As factories become more digitised, systems are increasingly networked, heightening the risk of critical data being spied on or tampered with. Historically, communication in automation relied on field buses like CAN and proprietary protocols, meaning an attacker needed physical access or a modem-connected telephone line to cause harm. It is easier for cyber-attackers to intrude into automation and control systems, manipulate them and even compromise machinery safety. The motivation for the attacks ranges from terrorism, industrial espionage, and sabotage to extortion. The widespread use of open-source software and consumer-grade components in automation increases vulnerabilities, as attackers often know their weaknesses. Consequently, data protection has become more crucial. Despite this, not everyone fully appreciates the importance of security. To prevent data breaches, essential security measures and practical solutions are crucial in the digital era. Machine builders, plant designers, installation engineers, and maintenance teams must understand their role in customer security strategies to ensure robust industrial protection. The objective of industrial security is to guarantee the availability of plant and machinery and the integrity and confidentiality of machine data and processes. Moreover, functional safety is addressed, emphasising that security and safety are interconnected for safe production processes. New standards like IEC 62443 have been developed to guide the step-by-step creation and implementation of a comprehensive industrial security strategy.

How do enhanced safety measures in robotics within the manufacturing process impact the production cycle times?

Automation is greatly impacted by robotics and artificial intelligence, which provide increased accuracy, effectiveness, and flexibility. Autonomous decision-making, adaptive learning, and predictive maintenance are made possible in automation processes by robotic systems that are coupled with AI-driven algorithms. Numerous robotic technologies, including autonomous mobile robots (AMRs) and collaborative robots (cobots), quickly and accurately customise automation-related processes. Robotic adoptions in various industries will continue to witness an exponential rise. Moreover, factories and plants look at humans and robots working together to increase efficiency and productivity. With robots and collaborative robots, the need for safety is also increasing. Machine builders and factory operators need to ensure that the machine design complies with the relevant safety standards, such as ISO 10218-2 (Robot and Robotic devices – Safety requirement for industrial robots.), ISO 13849 (performance levels for robotic installations) and ISO/TS 15066 (Collaborative Robot and Robotic Devices, Collaborative Robots). Robotics at Pilz consists of ROS modules for the industrial environment, service robotics, and the collision measurement set PRMS for human-robot collaboration (MRK). So, Pilz provides reliable support as you work towards your safe application.

How does Pilz ensure machinery safety and industrial security with its product offerings?

We offer a comprehensive range of solutions for machinery safety and industrial security. Our advanced sensor technology includes products like PSENmgate, PSENmlock mini, PSENslock 2, and other safety switches with guard locking. We also provide electromechanical and small safety switches for specific applications. Our safety light curtains are available for industries such as packaging, manual workstations, access guarding on conveyors or material handling with robots. Safety scanners are used for two-dimensional area monitoring with configurable warnings and protected fields, making them adaptable to various applications. Our safe radar systems provide robust protection, even when optical sensors reach their limits, offering a complete solution when combined with our safe control technology.

In control technology, our Sigma series and the modular safety relay myPNOZ are notable for their flexibility and customisation. The PNOZmulti 2 family of small safety controllers, including the standalone and compact PNOZ m C0, manage multiple safety functions and are configured with the PNOZmulti Configurator. The PSS4000 controller handles complex automation tasks reliably and is supported by PAS4000 software tools for configuration, programming, and diagnostics. These controllers and software tools create a seamless safety network, ensuring optimal performance and protection. All security risks in a product should already be identified during the development process and eliminated if possible. The international security standard IEC 62443 defines the requirements for this development process. TÜV Süd has confirmed that the Pilz development process meets this standard. We develop safely and securely. We focus on industrial security, adhere to security norms, and offer free webinars and the CESA qualification program. Our Identification and Access Management (IAM) system, with PITmode fusion technology, manages access permissions using RFID key authentication, enhancing security and preventing unauthorised use. IO-Link safety simplifies field-level communication, making factory automation more secure and efficient, and offers new possibilities for data diagnostics. We also support customers with operator and visualisation systems to ensure compliance with standards.

How can manufacturers overcome challenges in robotics integration to fully leverage automation benefits?

Understanding the requirements and challenges associated with robot integration is important. Before the robotic integration process, while assessing the risk, companies shall look out for the probable hazards that can arise from integrating robots and existing systems. Verifying whether existing safety measures associated with robotics are sufficient or not is crucial. Implementing rigorous safety standards is essential to protect workers.  The closer humans and machines work together, the more efficient work practices become. However, safe interaction between humans and robots increasingly demands new technologies and solutions. Also, the demands on safety increase the closer humans and machines get to each other.

Integrating robotics into existing manufacturing systems can present several challenges, but with the right approach and solutions, the benefits of robotic automation can be fully realised. Understanding the requirements and challenges associated with robot integration is crucial. Before the integration process, companies must assess the risks and identify potential hazards that could arise from integrating robots with existing systems. Verifying whether the existing safety measures are sufficient is critical. Implementing rigorous safety standards is essential to protect workers, and Pilz’s comprehensive safety solutions, including safety relays, controllers, and sensors, can be used to create a safe working environment. When assessing the risk with the Robotics aspect, if a machine has already been accredited with CE marking, integrating a new robot can introduce new hazards. In such cases, a new CE marking can be required, and a machine risk assessment must be carried out to confirm the new CE requirement. Pilz’s safety consulting services can assist with this process, ensuring compliance and safety.

Another crucial step is ensuring compatibility between new robotic systems and existing equipment and processes. Pilz provides safety controllers and sensors that seamlessly integrate with various robotic systems, ensuring smooth and safe operations.

It’s important to reference relevant robotic standards, such as ISO 10218 for industrial robots and ISO/TS 15066 for collaborative robots, to ensure compliance and safety. Each robot application must be considered individually in terms of safety. Pilz provides support with a range of services tailored to the individual life phases of a robot system, From application analysis to risk assessment by EN ISO 12100 through to CE marking. Our safety solutions meet the specifications of DIN EN ISO 10218-2 and ISO/TS 15066. We also offer a range of training offerings on robot safety.

In conclusion, Pilz provides a comprehensive approach to robotic integration, addressing the challenges and ensuring that the benefits of robotic automation are achieved.  We ensure full compliance with the New Machinery Regulation and CE marking requirements for all projects, prioritising safety and regulatory adherence in every solution we deliver.