“Decentralized safety is the key to modular machines.”

What does TURCK's safety portfolio include and how do your customers benefit from the cooperation with Banner?

Michael Flesch (Product Manager Safety Systems): Looking at TURCK products alone, our safety portfolio is very focused. It essentially consists of fieldbus modules for various control architectures. The yellow TBPN modules are for Profinet with Profisafe, the red TBIP modules for Ethernet/IP with CIP Safety. Our new TBEN hybrid modules, which combine safe and standard I/O in a single device, are in particularly high demand. Our portfolio is complemented by IP65-protected switch boxes for safe shutdown in voltage strings. Our IP67-protected decoupling boxes separate OSSD signals into two-channel switching relay contacts, providing safe relay outputs for frequency converters or robots, for example. In addition, we offer a comprehensive range of cables and connection components.

If you need more than that, our partnership with Banner is a great advantage, as Banner contributes a huge portfolio of safety components such as safety relays, controllers, light barriers, and switches. This enables us to offer complete, tailor-made safety solutions that go far beyond what we could cover on our own.

What is special about the hybrid modules and how do they differ from the full modules?

Hybrid modules combine safe and standard I/Os in one device. Typically, they have safe inputs, a configurable combo port that can be parameterized as a safe input or output, and digital inputs and outputs, some of which can be safely disabled. This significantly reduces space requirements and wiring effort. With hybrid modules, one side is a complete safety system with safe inputs, while the other side can be used flexibly for standard I/Os. The safe shutdown of individual ports is a special feature that increases flexibility in machine design.

How does TURCK position itself in the market for safety solutions – as a niche provider or as a full-range supplier?

We see ourselves as a provider of safety solutions in machine and plant engineering, even though we are particularly strong in certain niches. Our focus is on IP67 applications and decentralized, control cabinet-free solutions. We are particularly successful in the area of modular machine concepts, as the demand for flexible and easy-to-install solutions is constantly growing. The advantages lie in faster commissioning, less wiring effort, and a high degree of flexibility for conversions or expansions.

The trend is toward switch cabinet-free automation. How do your customers benefit from this in concrete terms?

Decentralized installation of the modules directly on the machine saves an enormous amount of time during installation and commissioning. Wiring becomes easier and sources of error are reduced. This is a decisive advantage, especially for production lines that change frequently or have a modular design. In addition, the modules are robust and designed for use in harsh industrial environments in accordance with protection class IP67. This not only facilitates installation, but also maintenance and expansion, as machine modules can be easily replaced or added.

TURCK is known for its multiprotocol modules. What about the safety modules?

Multiprotocol capability has long been standard in our standard I/O modules. These modules automatically detect whether they are operating with Profinet, Ethernet/IP, or Modbus and adjust themselves accordingly. The situation is somewhat more complex with safety modules: Currently, there are separate modules for Profinet/Profisafe (TBPN) and Ethernet/IP/CIP Safety (TBIP). A true multiprotocol safety module that combines all three protocols in one device is currently in development and is expected to be available soon. The goal is to enable customers to always use the same module regardless of the control system used, which significantly simplifies inventory management and planning. The standard multiprotocol modules can already automatically detect the appropriate protocol and configure themselves accordingly.

What are the technical challenges involved in developing true multiprotocol safety modules?

The biggest challenge is the secure separation of protocols and ensuring that safety-related data is transmitted correctly and reliably. In safety applications, protocols such as Profinet/Profisafe and Ethernet/IP/CIP Safety must not be mixed, as they have different requirements for secure communication. That is why we are working on so-called donor modules that enable the secure coupling of the different protocol worlds. These modules are still in development but should be available in the near future. The aim is to further reduce complexity for the user and increase flexibility.

What is special about the "TURCK Safe Link" protocol and how does it work?

TURCK Safe Link is a specially developed, application-optimized security protocol that enables secure communication between up to 31 modules – without the need for a central security control system. The modules are connected via the same network as Profinet, Ethernet/IP, or Modbus. One module takes on the role of host, while the others act as devices. The host recognizes the devices and enables secure data exchange, regardless of whether a controller is connected or not. This is particularly practical for modular machines that need to be flexibly expanded or retrofitted. The safety functions are always retained, which significantly increases flexibility and cost-effectiveness.

How does TURCK Safe Link differ from other safety protocols?

The big difference is that TURCK Safe Link does not require a central safety controller. While Profisafe or CIP Safety always require a controller as the master, the TURCK modules can communicate with each other independently. This reduces costs, simplifies system planning, and allows machine modules to be operated or maintained independently of each other. The technology is based on a collaboration with Bihl+Wiedemann, but has been specially adapted to our requirements and is not directly compatible with their Safe Link solution.

Which applications benefit particularly from Safe Link and decentralized safety solutions?

Our solutions are ideal for small to medium-sized machines and systems where modularity, flexibility, and fast commissioning are paramount. Typical applications can be found in the packaging industry, in special machine construction, and in assembly automation. Our decentralized safety modules really come into their own in production lines that change frequently or in machines that need to be retooled often. Multiprotocol capability is also a big plus for machine builders who export worldwide, because they don't have to commit to a specific control system.

What future technologies and developments are planned in the area of safety?

TURCK plans to continuously expand its safety portfolio, particularly in the area of intelligent, networked, and decentralized safety technology. We want to meet customer requirements and also securely establish our other field systems such as Ethercat and CC-Link. In addition, we are working intensively on true multiprotocol safety modules that combine all common protocols in one device. We are also developing new switch boxes and components that are even more flexible and powerful. Another focus is on the integration of IO-Link Safety in order to fully exploit the advantages of digital communication in the safety sector as well. The goal is to always be able to offer our customers the most flexible and future-proof solutions.