Emerson sends few news items these days. I’m not even invited to events. This news item intrigued me partly because I’ve heard almost nothing about safety controllers for years. I’m no longer familiar with the PACSystems product line that Emerson acquired several years ago. I imagine this upgrade will benefit their users specifying for a new project.
News in brief:
PACSystems Safety Controller enables SIL2 designs with pre-built templates for reliable performance in demanding, safety-critical applications
A few more details:
Emerson has announced the new PACSystems RX3i CPS400 Safety Controller, designed to enable Safety Integrity Level 2 (SIL2) strategies for infrastructure, fire and gas, burner management systems, and other emergency shutdown systems. The PACSystems Safety Controller is a compact, high-performance solution with robust security measures and a scalable architecture with 2,000 available I/O points, ideal for complex projects with evolving requirements.
A large 64-megabyte memory capacity and scalable digital architecture enables the PACSystems Safety Controller to support a diverse range of mission-critical applications. Using built-in industrial communications protocols, including OPC UA, Ethernet Global Data (EGD), and Modbus TCP, the RX3i CPS400 controller is ready to connect peer-to-peer and with higher level hosts, providing complete operational visibility.
Data integrity.
As a secure-by-design solution incorporating Secure Boot® and the Trusted Platform Module (TPM) standard, the new controller delivers rigorous data integrity and protection against potential threats. Safety-certified function blocks and pre-configured templates simplify overall system certification in accordance with the IEC 61511 standard.
Available in simplex or redundant controller configurations, the RX3i CPS400 controller can perform all safety data messaging with duplex communications using the black channel principle over EGD, allowing standardized and reliable connectivity with Emerson´s PACSystems VersaMax SafetyNet I/O system. The platform is IEC 61508 safety-certified, providing a capable SIL2 simplified solution to help designers build appropriate protection schemes.
It seemed as if technology and applications for industrial robotics had stagnated for quite some time. The last few years have witnessed advances on many robotic fronts. It seems fitting that updated industrial robot safety standards are releasing.
The Association for Advancing Automation (A3) has announced the conclusion of eight years of work with the publication of the revised ISO 10218, the global flagship standard for industrial robot safety. In its first major revision since 2011, these new documents offer a leap forward in ensuring the safety of robotics in industrial environments.
The two main areas of concern include Safety Requirements for Industrial Robots (Manufacturers) and Safety Requirements for Industrial Robot Applications and Robot Cells (System Integrators).
Here’s what’s new:
Clarified functional safety requirements for easier compliance and reduced risk
First-time inclusion of cybersecurity standards for industrial robot safety
Simplified guidance for collaborative robots (previously separate in ISO/TS 15066)
New robot classifications & test methodologies
“Working alongside hundreds of global experts, A3 played a pivotal role in shepherding this update to publication, to refine safety requirements in response to evolving automation technologies and workplace demands,” said Jeff Burnstein, A3 president. “This effort reflects A3’s ongoing commitment to enhancing robotic safety and supporting the widespread adoption of automation.”
The new ISO 10218 Parts 1 and 2 feature extensive updates that focus on making functional safety requirements more explicit rather than implied. This shift enhances clarity and usability, making compliance more straightforward for manufacturers and integrators alike.
In North America, ISO 10218 had been previously adopted as ANSI R15.06 in the United States and CSA Z434 in Canada. Work is underway to adopt the new 10218 in both jurisdictions with new versions of R15.06 and Z434 expected to be released later this year.
Key Updates in ISO 10218 (2025)
ISO 10218 consists of two parts:
Part 1: Safety Requirements for Industrial Robots (Manufacturers)
Part 2: Safety Requirements for Industrial Robot Applications and Robot Cells (System Integrators)
Clarified functional safety requirements that offer more precise safety guidelines to enhance compliance and risk mitigation.
Integrated safety requirements for collaborative robot applications that consolidates the previously separate ISO/TS 15066.
Incorporated safety guidance for manual load/unload procedures and end-effectors (sometimes called end-of-arm tooling or EOAT) from previously separate technical reports (TR 20218-1 and TR 20218-2).
New robot classifications with corresponding functional safety requirements and test methodologies.
Cybersecurity requirements pertaining to industrial robot safety.
Carole Franklin, director of standards at A3 Robotics, emphasized the significance of these updates: “With automation evolving at an unprecedented pace, it is essential that safety standards keep up with the latest advancements. This is a critical step in ensuring that as automation grows, worker safety remains a top priority. These revisions provide clearer guidelines and new classifications that will help manufacturers and system integrators implement the latest technology for safer robotic solutions.”
The 2025 edition of ISO 10218 is now available for purchase to U.S. customers through A3. Companies and professionals looking to stay compliant with the latest safety requirements can acquire the standard through our webstore. Pricing starts at $244 USD, with options available for digital bundles.
Yokogawa has sent a couple of process automation announcements recently. It’s been quiet on my radar for a few years. Nice to see some investment in product development. The first is the release of OpreX Robot Management Core, an application in the Asset Management and Integrity family. The second concerns strengthened industrial network support in CENTUM in the Control and Safety System family of solutions.
OpreX Robot Management Core
Yokogawa Electric Corp. announces the development and release of OpreX Robot Management Core, a software application in the OpreX Asset Management and Integrity family.
OpreX Robot Management Core is a key product in the Yokogawa robot operations solution. By integrating the management of various types of robots that perform plant maintenance tasks conventionally carried out by humans, this software will help customers maintain their facilities in a safer and more efficient manner. In addition, when connected to a plant’s control and safety systems, it enables the utilization of manufacturing site data that has been acquired by robots, and the issuing of procedural instructions to robots, thus enabling the first step to be taken toward autonomous plant operations.
In plants that have been designed around people, there is a need for the efficient management of different types of robots to carry out a variety of tasks. In response to this need, Yokogawa began discussions with robot manufacturers in 2019 and in the following year went on to develop a prototype robot management and operations platform that has since been used in proof-of-concept field tests with several customers. Leveraging the experience gained through these tests, Yokogawa has developed this software to make it easier to introduce robots in plants.
OpreX Robot Management Core is a software application that improves safety and efficiency in plant maintenance operations by facilitating the utilization of robots. Depending on customer requirements, it can be provided for use in either an on-premises or cloud environment.
1. Integrated management of different types of robots
This software enables the registration, management, and operation of multiple types of robots in a unified manner. It supports the Spot four-legged robot from Boston Dynamics and the EX ROVR autonomous, explosion-proof, plant inspection robot from Mitsubishi Heavy Industries. The software’s management screen, which allows users to check the status of individual robots, is viewed in a web browser, enabling remote operations.
2. Connection with other systems
This product was developed with the ability to link to Yokogawa’s OpreX Collaborative Information Server. When doing so, the data collected by robots can be combined with data from control systems, safety instrumented systems, and integrated asset management systems for centralized management. This means that application development and data analysis can also be performed easily not just for maintenance tasks, but other operational tasks too. If an interface for robot utilization is built on the OpreX Collaborative Information Server, this enables the dispatch of robots to plant sites and the performance of safety inspections based on alarms detected.
The development of OpreX Robot Management Core enables Yokogawa to fully rollout its robot operations solution aimed at increasing workplace safety. By providing consulting, assistance in the selection and procurement of hardware and software from strategic partners and other sources, and engineering, operational support and other services, Yokogawa is able to help customers resolve issues encountered in their businesses and can develop specific robot and drone applications. Through this one-stop solution, Yokogawa will ensure the reliability, availability, and sustainability of robot operations and help to achieve autonomous plant operations.
Yokogawa Upgrades the CENTUM VP Integrated Production Control System
Yokogawa Electric Corp. announces the May 31, 2024 release of CENTUM VP R6.11.10, an enhanced version of the CENTUM VP integrated production control system that is a core product in the OpreX Control and Safety System family of solutions.
With this new version of CENTUM VP, plant uptime is improved through the addition of a redundancy function to a new IO card that supports communications via the PROFINET communications protocol for industrial networks. Furthermore, to reduce project costs and improve efficiency in plant operations, functional enhancements have been made to the Unified Alarms and Conditions Server (UACS) and the CCC Inside for the Yokogawa CENTUM VP compressor control solution.
Yokogawa has developed a new PROFINET IO card that supports a redundancy function, and by doing so, has made high reliability and high uptime a reality.
Often by the time a tech or business story hits mainstream media or politics the situation is on the downward slope of the sine wave. There was a story in The New York Times today about pollution and emissions from petrochemical plants. Surely that has been a big problem. But companies have been tackling the problem for a while, now. Here is a story from ABB which has developed technology applications to find methane leakages so that they may be repaired.
ABB’s proven emissions monitoring technology now extends to tackling the massive environmental problem of millions of leaking orphan oil and gas wells
ABB’s OA-ICOS laser-based technology has a track record of providing trustworthy measurements of greenhouse gases that are recognized by global industry bodies, research centers and environmental protection agencies
By supporting the work on plugging decomissioned wells in the United States, the technology helps in the fight against climate change
ABB’s emissions monitoring technology which is typically used for gas leak detection by oil and gas companies and natural gas utilities is now employed to identify and monitor orphan wells in the United States.
With the help of ABB technology, organizations such as The Well Done Foundation, the nonprofit organization that works to plug orphan oil and gas wells in the country, can detect leaking wells and, once the wells are capped, continue to monitor the sites to ensure they no longer emit harmful greenhouse gases.
Orphan wells are oil or gas wells that have been deactivated and no longer have legal owners responsible for their care. Due to their age and deteriorated condition, the wells can leak methane and other harmful greenhouse gases through their “plugs”.
The United States Environmental Protection Agency estimates that methane emissions from over 2 million inactive, unplugged wells, of which orphan wells are a subset, range from a CO2 equivalent of 7 to 20 million metric tons per year (approximately the emissions of 2 to 5 million cars). Methane has more than 80 times the warming power of carbon dioxide over the first 20 years after it reaches the atmosphere, according to the Environment Defense Fund.
Many wells are situated on farmland, and could contaminate land, air and water, potentially harming ecosystems, wildlife, livestock, and people.
In some parts of the United States where towns are growing, housing has been built where oil and gas wells once stood. The Environment Defense Fund estimates that 14 million Americans live within a mile of an orphan well.
“It is extremely rewarding to see our technologies employed in the endeavor of fixing such a pressing environmental problem. We remain focused on accelerating the pace of environmental programs that reduce emissions, especially in the oil and gas industry. Our work on this initiative is a great example of how technology can benefit the environment and help countries achieve their sustainability goals,” says Jacques Mulbert, Division President, ABB Measurement & Analytics.
What can be measured can be improved
Together with channel partner Winn-Marion, ABB worked to create a comprehensive approach that enables the identification, on-site qualification, and monitoring of orphan wells. At the heart of the solution are ABB’s gas leak detection products as well as a suite of flow computers, both used in tens of thousands of industrial plants worldwide to measure and report on emissions.
Initially, ABB’s gas leak detection system is used to find the orphan wells. Depending on their location, the high sensitivity analyzers using OA-ICOS technology are transported by vehicle (using ABB Ability™ MobileGuard), drone (HoverGuard), or backpack (MicroGuard) to the site. The system can detect methane emissions down to 1 part per billion (ppb).
Once on-site, it measures methane concentration and flow with a measuring range as low as 180kg/h. The flow from the thermal mass is logged and visualized on ABB’s gas flow computers, the control devices known in the industry for their extreme accuracy and reliability. In the post-plugging phase, methane emissions continue to be monitored.
A key advantage of ABB’s emissions monitoring technology is that it is fully audited by the Bureau of Land Management, which manages the Federal government’s onshore oil and gas program in the United States.
The Rockwell Automation PR team must have worked overtime following November’s Automation Fair. Here are a number of releases on new products and services. These cover a spectrum of technology areas that further reveal the breadth of Rockwell’s reach.
Smart Machine Development
GuardLink with EtherNet/IP
FactoryTalk Logix Echo
Cyber Endpoint Protection Services
Simplify Smart Machine Development with Improved Micro800 Controllers and Design Software
Machine builders can save engineering time and costs with the enhanced Allen-Bradley Micro850 and Micro870 2080-Lx0E controllers using the latest Connected Components Workbench software from Rockwell Automation.
Class 1 implicit messaging capability up to eight EtherNet/IP devices support
Streamline integration of controller to drives, supporting PowerFlex 520 series and Kinetix 5100 drives over EtherNet/IP with pre-defined tags and pre-developed user-defined function block (UDFB) instructions.
Connected Components Workbench software version 21 required.
GuardLink 2.0 with new EtherNet/IP Interface
GuardLink 2.0 offers advanced diagnostics by way of the new Allen-Bradley 432ES GuardLink EtherNet/IP On-Machine Interface or a combination of Dual GuardLink Relay and EtherNet/IP Interface.
GuardLink 2.0 protocol also enables safety-rated control device status reporting and automatic diagnostic reporting to an HMI using CIP Safety over EtherNet/IP.
Connect up to 96 safety devices via three independent safety channels.
The interface can cascade power to additional interfaces and can keep track of timing and frequency of events to improve maintenance and create process efficiencies.
The 432ES supports linear, star and Device Level Ring topologies while meeting safety ratings up to SIL 3, Cat 4 PLe.
New Capabilities in Emulation and Support with First expansion of FactoryTalk Logix Echo
Attention was dedicated to improving testing, giving users access to more than 20 variations of the 5580 ControlLogix platform at their disposal.
FactoryTalk Logix Echo simplifies the emulator experience by providing users the opportunity to download directly to FactoryTalk Logix Echo without modifications.
Having the emulation of the 5580 ControlLogix Ethernet port means that to other software, FactoryTalk Logix Echo looks like another controller, offering flexibility to expand your emulation to visualization or other controllers.
Version 2 will be the first emulation platform to support safety controllers by introducing GuardLogix 5580 controller catalogs.
The inaugural version supported one 17 slot chassis, but the latest release now supports the creation and communication of multiple chassis with one FactoryTalk Logix Echo license.
Comprehensive Endpoint Protection Services
For organizations to secure their operations and reduce cyber threats, a successful cybersecurity strategy requires solutions to secure endpoints – any device that is connected to a network outside of its firewall, including laptops, HMIs, switches, IoT devices, and more.
Rockwell Automation and CrowdStrike are providing manufacturers with comprehensive Endpoint Protection Services, combining Rockwell Automation’s Industrial Cybersecurity Services and CrowdStrike Falcon platform to monitor, protect, investigate, and respond to incidents.
Purpose-built in the cloud with a single lightweight-agent architecture, the CrowdStrike Falcon platform delivers rapid and scalable deployment, superior protection and performance, reduced complexity, and immediate time-to-value.
When customers choose the CrowdStrike Falcon platform through Rockwell Automation, they receive the industry-leading software coupled with OT-specific Falcon policies, developed by Rockwell Automation cybersecurity specialists, and backed by software and phone support.
Endpoint Protection fits into the expansive Rockwell Automation portfolio of Managed Services along with Incident Response and Threat Detection to provide customers with a holistic cybersecurity solution.
While we are on a robot/human collaboration theme, take a look at this exoskeleton from WearTech Center. The evolution of ergonomics and human-assist tech has fascinated me for a very long time. I’m old enough to remember the hard and dangerous ways. Given some of the stuff I’ve done early in my career, I’m lucky to be hear with all my extremities intact.
The WearTech Center, an applied research center accelerating the development of emerging technology products, along with Arizona-based wearable device companies GoX Labs and AKE, and Arizona State University’s top mechanical engineering researchers, are advancing worker wellness and safety with new exoskeleton technology. Through the public-private collaboration, Arizona-based innovators announced they are developing a new exoskeleton that will make workplaces safer for millions of workers in many industries. The wearable exoskeleton technology called PhenEx will help workers squat and lift heavy loads promoting overall worker health.
Previously, GoX Labs, AKE and ASU successfully developed a similar ex called the Aerial Porters Exoskeleton, or APEx. More than $31 million is spent annually in disability benefits for retired aerial porters, who had a high incidence of musculoskeletal injuries, according to a U.S. Department of Transportation’s Volpe Center study. To promote worker wellness and make pushing and lifting easier and safer, APEx is designed to assist people in loading a 10,000-pound pallet and pushing it onto an airplane.
“There are 89 million workers exposed to injury at work every day. As Arizona continues to grow as a hub for many different industries, the need for exoskeletons that promote workplace wellness only increases. Working through the WearTech Center to collaborate with ASU’s researchers gives us the push we need to take our technology to the next level,” said Dr. Joseph Hitt, CEO of GoX Labs.
At the WearTech Center, GoX Labs’ and AKE’s exoskeleton technology product development follows the applied research model which accelerates the process via collaboration with public and private sectors partners. The center shepherds these innovative products through the idea generation, project formation, validation, and commercialization phases.
“Innovations like what GoX Labs, AKE and ASU are developing through the WearTech Center have a high impact on reducing workplace injuries and enhancing Arizona’s economic development,” said Wes Gullett, Operations Director of Applied Research Centers for the Partnership for Economic Innovation. “The Arizona Legislature’s public investment in applied research capabilities and our ability to connect innovators to the tools they need to accelerate their product’s development grows Arizona’s economy and fuels its innovation opportunities.”
APEx is already being used by the U.S. Air Force by aerial porters to load heavy cargo onto planes. GoX Labs, AKE and ASU are continuing their collaborative efforts creating the quasi-active exoskeleton PhenEx with the support of the WearTech Center. The wearable PhenEx leverages sensors to activate spring elements when workers need to perform physical activities for their jobs. The quasi-active exoskeleton unlocks when the worker is at rest, walking or driving as to not hinder motion. The WearTech Center will assist with applied research and testing for product development.
GoX Labs and AKE will test out PhenEX on local employers like Amazon, Lucid Motors, and other industry partners through WearTech. Arizona employers can get involved in the testing of PhenEx by emailing [email protected].
