Rosendahl Nextrom manufactures production machinery for the battery, cable and wire, and optical fiber industries. Due to high rotation speeds in its plants, the customer faced increasingly stringent safety requirements alongside strict demands for system performance and quality.
Key objectives included:

• Ensuring an immediate, simultaneous safe stop across entire multi-machine lines when an emergency or fault occurs.
• Implementing a modular safety solution compatible with varying machine configurations and diverse motors and drives.
• Avoiding the excessive wiring and engineering complexity typically required for line-wide safety systems.

Siemens and Rosendahl Nextrom implemented a standardized safety concept across its machines and plants based on Siemens Safety Integrated within Totally Integrated Automation (TIA):

• Mechanical & Inherent Safety: Basic injury prevention through optimized mechanical design (eliminating sharp edges and crush points) combined with optical and mechanical safety components.
• Control & Distributed Safety: Fail-safe SIMATIC S7-1500 CPUs and SIMATIC ET 200SP distributed I/O systems execute the safety logic. Depending on machine type and required performance level, dual-channel monitoring and disconnecting systems are implemented.
• Drive Safety Functions: SINAMICS converters provide certified, drive-based safety functions (STO, SS1, SLS, and SOS) for safe motor control across diverse drive configurations.
• Line-Wide Coordination via PROFIsafe: Safety communication runs over the standard fieldbus using PROFIsafe. If an emergency or fault triggers on one machine unit, all other units across the production line stop or reduce to a safe speed simultaneously.
• Unified Engineering: Standard automation and safety functions are engineered, configured, tested, and documented within the TIA Portal framework.