More Input on Intrinsic Safety

April 3, 2009
Competition in this arena is heating up, says ARC Advisory Group.

Factory automation safety networks are emerging as the next competitive battleground in the automation network wars. Drawing on legacy battles in areas such as serial-based device networks, process fieldbuses and Ethernet-based automation networks, suppliers and network trade associations alike are ramping up their arsenals for competition in this increasingly important arena. This race will fuel growth in the worldwide market for factory automation safety networks at a compounded annual growth rate (CAGR) of 39.3% over the next five years. The market totaled less than 700,000 nodes in 2008, a figure that’s projected to grow to over 3.6 million in 2013, according to a new study by ARC Advisory Group.

“The safety network market will benefit from the same quantifiable cost savings in areas such as wiring and installation that fueled adoption of standard device networks over hardwiring, plus they can deliver concrete business benefits in areas such as regulatory compliance and reduced shutdowns. The timing and impact of safety regulations remains a wild card in many parts of the world, but both existing suppliers and new entrants are lining up their safety network strategies as the technology increasingly emerges as a key differentiator,” according to Chantal Polsonetti, ARC’s vice president and principal author of the report, “Factory Automation Safety Networks Worldwide Outlook.”

Growth in the safety network market will parallel that of serial-based device networks from the perspective of the wiring savings a bus-based network can deliver relative to hardwiring of safety components. These savings are realized in areas such as reduced cable costs, smaller panels and cable trays, fewer components required, reduced cost of wire installation, and greater flexibility in reconfiguring the network as operations dictate. Increasing availability of light curtains, safety switches and other safe components with a network interface will only further the potential cost savings in this area. Growth in interest in wireless safety devices will further fuel cabling and installation savings.

Limiting the operational impact of a safety event is another benefit derived from use of safety networks. Ability to implement controlled or isolated shutdowns by decelerating motors or isolating emergency stops to specific zones has significant benefits relative to tripped e-stops or light curtains initiating complete system shutdowns and often time-consuming restarts. Servo drive manufacturers have recognized this trend and are moving toward integrated safety network components for their drive systems that allow controlled or limited shutdowns.

Integration of safety functionality into servo drives and other motion control equipment is one of the most intriguing drivers in the factory automation safety marketplace. Embedding a safety controller and safe I/O right into a servo drive with a soft starter eliminates the need for a separate safety controller and I/O. Safety functions are integrated directly into the drive, eliminating the need for external power contactors and speed monitoring equipment and enabling local control.

A complete, detailed version of this report is available from ARC Advisory Group.