SIEMENS

1. Core Host: SIMATIC S7-1500F Fault Safety PLC (F-CPU)
   In the figure, the main body is the S7-1500F safety CPU. It is similar to the mainstream models in appearance:
   CPU 1511F-1 PN (small safety device)
   CPU 1513F-1 PN (most commonly used for medium and small-sized equipment)
   CPU 1515F-2 PN / 1516F-3 PN (medium and large production lines)
   The yellow terminal module on the body is the F safety I/O module (fault safety input and output), specifically handling safety circuit signals (emergency stop, safety door, grating, etc.).
2. Distributed IO below: SIMATIC ET 200SP
   The green network cable connects to the ET200SP distributed remote IO station. The IM155-6 PN interface module acts as a Profinet bus adapter, and is also equipped with the yellow F safety module to achieve remote collection and output of safety signals (emergency stop, safety door, grating, etc.).
   The entire system is collectively referred to as
   Siemens SIMATIC Safety Fault Safety Automation System (S7-1500F + ET200SP F-IO), compatible with the PROFIsafe safety bus protocol.
   II. Core Functions of Each Component
3. S7-1500F Safety CPU (the control brain of the entire equipment)
   Basic general control functions (the same as the ordinary S7-1500)
   Logic operation control: Receives sensor signals, automatically controls motors, cylinders, valves, servo and other actuators according to the programmed program, completing the equipment automation process (assembly line, machine tool, packaging machine actions).
   Motion control: Comes with high-speed motion instructions, directly controls V90/S120 servo motors, achieving positioning, synchronization, electronic cam, multi-axis linkage.
   Process integration: Built-in PID temperature / pressure closed-loop, counting, PWM pulse, cam control functions, without additional modules.
   Industrial communication: Comes with a Profinet Ethernet interface, and communicates with touch screens, upper computers, frequency converters, and remote IO at high speed. The green network cable is the Profinet bus.
   Diagnosis and maintenance: Comes with a display screen that can directly view fault codes and operating status. Full-link hardware self-diagnosis, quickly locating disconnected or short-circuit faults.
   Unique feature of the F model: Fault safety (Safety) function (the core difference from the ordinary S7-1500)
   Safety redundant calculation: Dual independent processors inside the CPU cross-check to prevent single hardware failure from causing safety loss, meeting industrial safety standards EN ISO 13849, IEC 61508 SIL2/SIL3.
   Independent control of safety circuits: Specifically handles safety signals: emergency stop button, safety grating, safety door switch, safety speed monitoring. When the equipment is abnormal, it forcibly cuts off power to avoid casualties.
   PROFIsafe safety bus: Remote control of ET200SP remote safety module through the network cable. Safety signals and ordinary control signals are transmitted through the same network cable, simplifying wiring.
   Safety program isolation: The safety logic is separately compiled and verified from the ordinary automation program to prevent ordinary program bugs from interfering with the safety protection logic. Remote expansion of IO points: When production line equipment is scattered, there is no need to pull back a large number of cables to the main control cabinet. IO modules can be installed nearby;
   Remote safety collection: The safety signals from remote workstations are transmitted back to S7-1500F through PROFIsafe;
   Modular design, allowing for free addition or removal of digital, analog, and safety modules, with strong scalability.
   III. Typical application scenarios
   This S7-1500F system with safety functions is used for automated equipment with personal safety risks and requiring mandatory safety certification:
   Automobile manufacturing: welding robots, stamping machines, painting lines;
   Large CNC machines, injection molding machines, large packaging assembly lines;
   Lifting, logistics vertical warehouses, lithium battery automated production lines;
   Chemical, water treatment process equipment with safety interlock requirements;
   Railway transportation, large test and experimentation platforms.
   IV. Supporting software
   The program is written using TIA Portal (Bechtel). The safety functions need to be combined with the STEP7 Safety Advanced safety software package to complete safety program compilation, safety signature, and safety acceptance.

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