Introduction: The Importance of Safety in Manufacturing Automation in 2026
Modern production systems require reliable and safety-compliant automation. The safety control system (Safety PLC) is responsible for performing functions that ensure safety when dangerous situations are detected, and plays a key role. In 2026, in Ukraine, as in the whole world, production will increasingly depend on high-precision and certified solutions that meet the requirements of SIL standards.
History of development: key stages
The development of safe automation began in the 1970s, when there was a need for systems that ensure safety in industrial installations. The first security systems were simple, but with the development of technology they became more complex and effective.
| year | Achievement |
|---|---|
| 1970 | The beginning of the use of primary safety systems in industrial production. |
| 1980 | Introduction of standards IEC 61508. |
| 1990 | Publication IEC 61511 for production processes. |
| 2000 | Development of high-precision Safety PLC based on modern digital technology. |
| 2010 | Implementation of SIL 3 in the practice of industrial systems. |
| 2020 | Use of SIL 4 in critical production systems. |
| 2026 | Increasing security requirements due to increasing automation in Ukraine. |
How they work: basic principles
Safety PLCs perform safety functions by performing a cycle of scanning, detecting dangerous conditions, and taking appropriate actions. Main stages:
- Scanning of incoming signals.
- Signal processing in a logic circuit.
- Execution of initial actions.
The formula for calculating the security level:
PFD = 1 - PFDavg where PFD is the probability of failure of the safety function, PFDavg is the average value.
Current state of technology
Today, modern Safety PLCs from the following manufacturers are available on the market:
- Siemens SIMATIC S7-1500 Safety — SIL 3 level, used in critical production.
- Beckhoff EL6103 - SIL 2 support, ideal for production with limited requirements.
- Schneider Electric Modicon M580 - SIL 3 support, used in large industrial installations.
These systems comply with the standards IEC 61508, IEC 61511, as well as DSTU 4332:2017.
Selection criteria: decision matrix
Choosing a Safety PLC depends on several factors. Below is a matrix for decision-making:
| Criterion | Siemens S7-1500 | Beckhoff EL6103 | Schneider M580 |
|---|---|---|---|
| SIL level | SIL 3 | SIL 2 | SIL 3 |
| Price | High | average | High |
| Medium durability | 10,000 hours | 7,500 hours | 9,000 hours |
| Compliance with standards | IEC 61508, EN ISO 13849-1 | IEC 61508, EN ISO 13849-1 | IEC 61508, EN ISO 13849-1 |
| Versatility | High | average | High |
Performance indicators: real comparison data
The table below provides additional performance and compatibility data for various models:
| Indicator | Siemens S7-1500 | Beckhoff EL6103 | Schneider M580 |
|---|---|---|---|
| Maximum speed | 100 kHz | 100 kHz | 100 kHz |
| Maximum number of incoming/outgoing | 128 | 64 | 128 |
| Compliance with standards | IEC 61508, EN ISO 13849-1 | IEC 61508, EN ISO 13849-1 | IEC 61508, EN ISO 13849-1 |
| Medium durability | 10,000 hours | 7,500 hours | 9,000 hours |
Potential problems when implementing in old installations
During the implementation of Safety PLC in old installations, the following problems may occur:
- Lack of redundancy in systems.
- It is necessary to modernize the infrastructure.
- Certification requirements.
Recommendations:
- Conduct an analysis of the current system.
- Modernize the infrastructure.
- Use certified components.
Future: Technology Development (2026–2030)
Between 2026 and 2030, security technologies that use AI and machine learning to predict failures are expected to develop. An important direction will be the growth of SIL levels to SIL 4, which requires high-precision solutions.
Sources
- IEC 61508:2010 - Security of automation systems.
- IEC 61511:2016 - Process safety.
- EN ISO 13849-1:2015 - Control security.
- Siemens Technical Documentation: SIMATIC S7-1500 Safety.
- Beckhoff White Paper: EL6103 Safety in Automation.
Conclusion
Choosing the right Safety PLC is critical to ensuring production safety. Use certified components that comply with standards and meet the requirements of your production. UNITEC-D is a reliable supplier of components for various security systems, conforming to DSTU, EN and ISO standards. Visit the UNITEC-D E-Catalog for more information.
