Mosaic System Safety, Ease to Use and Flexibility
Published on : Monday 01-07-2024
Mosaic is a modular, configurable safety controller for protecting machines or plants.
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The reasons for success of the ReeR’s products used in the world of packaging and logistics, increase thanks to the modular configurable safety controller “Mosaic”.
To the traditional strengths: quick installation, integration of all required functions for palletizing systems (such as Muting and Override) and compliance with the safety requirements the security parameters, are added the flexibility and possibility of future expansion of the safety system typical of the Configurable Safety Integrated controller.
Today, not to mention the significant regulatory changes related to the safety of the machines introduced since 2023, the design and construction of the safety of a complex logistic centre, depends largely by economic factors and needs of expansion and changes that over time could affect some machinery or whole plant parts. Mosaic solution meets this requirement.
Mosaic is a modular, configurable safety controller for protecting machines or plants. With Mosaic you can plan the project for the security taking into account the possible expansions, integrations and modifications of machinery.
All controls concentrated on the main unit and expansion modules
Depending on the complexity of the system, the system can be composed or from the single main unit (module Master) or, in maximum configuration, from the
main unit (module Master M1S COM) and 14 expansions (total of 128 input, 32 fieldbus inputs, 32 OSSD pairs, and 48 signaling status outputs).
Mosaic can monitor several safety sensors and commands including encoder and proximity for safety speed monitoring.
Expansion units are also available to permit connection for diagnostics purposes to the most common industrial Fieldbus systems.
The MCT1 and MCT2 interface modules allow the de-centralisation of the modules that comprise the safety system.
This solution is ideal for connecting multiple machines on a production line.
Examples of application
Palletizing systems protection
Protect palletizing systems for sacks or material not easily stacked, with the presence of seams, labels and protrusions that may making irregular the geometric shape of the pallet and thereby cause false signals from the sensors.
To solve the problem and achieve high reliability of operation of the plant while ensuring all safety requirements, the light curtains and muting sensors used are handled by the Mosaic Safety Controller. This solution, in addition to ensuring the functionality preventing undesirable stops due to false signals, allows you to easily adapt the system to the safety features of the system in accordance with the IEC TS 62046 and other existing rules.
In the plant, to protect the access gates, have been implemented:
• One-way openings with pallet exit
The sensors are on the same side of the vertical light curtain and are placed in front of the guarded opening.
• Two-way openings with pallet entrance/exit
The Muting sensors are the first on one side and the second on the other in relation to the vertical light curtain.
All timings of the system and management of muting functions are configurable by the safety controller Mosaic. This allows maximum versatility of the plant.
Analogue sensor control
With 2 or 4 independent isolated analogue channels (500 V), that can be paired-up to allow sensor reading redundancy, the MA2 or MA4 modules allow the connection of analogue sensors to the Mosaic system.
These modules can be used for any application requiring analogic sensors connection as loading cells, pressure switches, temperature measurements, flow and level measurements, etc.
2 MA2 or 4 MA4 analogue inputs. Each channel can detect a 4-20 mA current or a 0-10 V voltage (selectable via software). Each channel can supply 24V DC up to 30 mA with 16 bit resolution.
MV0, MV1 and MV2 expansion module for safety speed monitoring (upto PL e) of two independent axes. Safety speed monitoring for: zero speed control, maximum speed, speed range and direction. Up to 4 logically selectable speed thresholds (freely configurable via MSD) for each logical output (axis). Input for TTL, HTL or Sin/Cos incremental encoders and PNP/NPN proximity switches.
Let's see some examples: Zero speed control: it is verifies that the dangerous device is actually standstill, and this allows you to unlock gates to allow an operator safe access to dangerous areas. Maximum speed control: it is verified that the safety speed set (reduced) is not exceeded. This allows to safety work during the operations of maintenance or adjustment of the system.
Remote configuration with the new M1S COM module
New M1S COM module enables Ethernet connection.
This module can handle up to 4 fieldbus interfaces with different protocols: Ethernet IP, EtherCAT, PROFINET, MODBUS TCP A remote connection with the M1S
COM module can be activated via the MSD software.
When Mosaic M1S COM is connected with a ModBus TCP o EtherNet/IP fieldbus, it is possible to choose if the stack automatically set the LAN parameters (DHCP active) or (selecting “Manual”) directly complete the necessary network parameters: IP Address, Subnet Mask, Default Gateway, etc.
With Profinet RT fieldbus, only the manual configuration of the necessary network parameters is required (IP Address, Subnet Mask, Default Gateway, Station Name When Mosaic M1S COM relates to an EtherCat Fieldbus, the necessary network parameters will be set directly by the EtherCat Master.
(Please refer to the Safety Guide on ReeR Website www.reersafety.com for more information.)
Founded in Turin (Italy) in 1959, ReeR distinguished itself for its strong commitment to innovation and technology. A steady growth throughout the years allowed ReeR to become a point of reference in the safety automation industry at a worldwide level. The Safety Division is in fact today a world leader in the development and manufacturing of safety optoelectronic sensors and controllers.
ReeR is ISO 9001, ISO 14001 and ISO 45001 certified.
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