Contact UsFunctional Safety Solutions for BLDC Motors
Functional safety in modern motion control is no longer about adding external components to a motor. It is about embedding intelligence directly into the drive system. In sectors like autonomous mobile robotics (AMRs), medical technology, and high-end industrial automation, the goal is to reduce complexity while hitting the highest possible safety ratings.By moving safety logic to the "edge" directly into the motor housing you eliminate the need for bulky external safety modules and drastically cut down on wiring costs and potential points of failure.
Global Safety Compliance
- ISO 13849-1: Safety of machinery - Safety-related parts of control systems
- IEC 61508: Functional safety of electrical/electronic/programmable electronic safety-related systems.
- IEC 61800-5-2: Adjustable speed electrical power drive systems - Safety requirements.
Integrated Safety Functionalities
We provide a comprehensive suite of safety functions (Safety Integrated) to cover every operational scenario:
- STO (Safe Torque Off): This is the fundamental safety feature. It electronically prevents the motor from creating torque, ensuring no accidental startups occur during maintenance or standby.
- SS1 (Safe Stop 1): This function executes a controlled, powered deceleration before triggering the STO state, protecting the mechanics from the stress of a hard stop.
- SLS (Safely Limited Speed): Essential for human-machine collaboration. It monitors the motor to ensure it never exceeds a pre-defined speed threshold.
- SBC (Safe Brake Control): Provides a safe output signal to control an external mechanical brake.
Product Matrix: Certified BLDC Drive Systems
We offer different tiers of integration depending on the risk assessment of your specific application.
| Series | Integrated Logic | Communication | Safety Functions | Certification |
|---|---|---|---|---|
| dSafe (BG 75 / 95) | Integrated Safe Motion | FSoE | STO, SS1, SLS, SBC | SIL 3 / PL e* |
| dPro (BG Series) | Integrated STO | CANopen, EtherCAT, PROFINET, EtherNet/IP | STO | SIL 2 / PL d |
| BGE 5510 / 8060* | External Controller with STO | CANopen, EtherCAT, PROFINET, EtherNet/IP | STO | SIL 2 / PL d |
| AFS58 Encoder | Safety Encoder | Sin/Cos | Safe Position Signal | SIL 2 / PL d |
Certified Hardware Lineup
The dSafe Series (BG 75 / BG 95):
This is the flagship for the most demanding applications. It features fully integrated safety logic within the motor. It supports FSoE (Fail Safe over EtherCAT) and PROFIsafe, meaning safety data travels over the existing network cable. This series is rated for SIL 3 / PL e*. (*certification in work)
The dPro Series:
A versatile solution for general automation. These smart BLDC motors come standard with a hardware-integrated STO. They are designed for applications requiring SIL 2 / PL d compliance without the need for complex bus-based safety.
External Control & Feedback:
For modular setups, the BGE 5510 and BGE 8060 external controllers provide certified STO inputs. This enables any BLDC motor to meet STO safety requirements.
Smarter System Integration:
The shift toward "Black Channel" communication (FSoE and PROFIsafe) means your safety PLC can talk directly to the motor over the standard ethernet bus. This removes the "spaghetti wiring" typically associated with safety circuits and allows for real-time diagnostics that can predict failures before they happen.
Implementation in the Field:
In a logistics warehouse, an robot AGV using these drives doesn't have to stop every time a person walks by. Using SLS, it simply slows down to a safe speed and continues its mission. In medical settings, the redundant architecture ensures that even if one sensor fails, the drive enters a safe state immediately, protecting the patient and the equipment.
Talk to an engineer about your risk assessment and let’s find the right drive configuration for your system.
Talk To An Expert
Safe Communication & System Integration
Eliminate discrete safety wiring. Our dSafe motors utilize black-channel communication, allowing safety-related data to be transmitted over the existing industrial Ethernet bus:
- FSoE (Fail Safe over EtherCAT): For ultra-high-speed, real-time safety response.
- PROFIsafe: Seamless integration into PROFINET-based Siemens/TIA environments.
- Hard-wired STO: Available for simpler systems requiring a direct physical connection to a safety relay.
Application Engineering: Why it Matters
- Mobile Robotics: Implement SLS to allow AGVs to operate at reduced speeds when humans are detected, maintaining productivity without sacrificing safety.
- Medical Technology: Redundant sensing and STO ensure that pumps or surgical robots remain in a safe state even during a component failure.
- Industrial Machining: SS1 allows for a faster return to operation after a safety interruption compared to an uncontrolled emergency stop.
Technical Support & Configuration
Selecting the right safety level (SIL vs. PL) depends on your specific Risk Assessment. Our application engineers are ready to assist you in selecting the motor, encoder, and protocol combination that meets your target Safety Integrity Level.
Contact our Safety ExpertsDownloads:
Related Press Releases
| Press Releases | Overview |
|---|---|
| E90R LN: Silent Fail-Safe Brake | This release features the E90R LN spring-applied brake, which uses a fail-safe principle to automatically engage and hold loads when de-energized. It focuses on reducing operating noise for sensitive environments like medical technology while maintaining uncompromising safety standards. |
| AFS 58: Smart Safety Meets Precision | Introduces the AFS 58 safety encoder, certified up to SIL2 and Performance Level d. It is designed for the BG 66, BG 75, and BG 95 motor series to provide reliable axis monitoring for position, speed, and direction. |
| BG 95: Award-Winning Safety | Recognizes the BG 95 dPro servo motor for its integrated safety features, specifically optimized for automated guided vehicles (AGVs). |
| dSafe: Integrated Motor Safety | Announces the launch of the dSafe technology for BG 75 and BG 95 motors. This platform integrates Safe Motion functions such as STO, SS1, and SLS directly into the motor, supporting safe communication via PROFIsafe and FSoE protocols. |
| BGE 8060: High Power STO Unit | Features the BGE 8060 dPro, a compact controller with a built-in STO safety function, designed for demanding high-power applications requiring up to 1800 W. |
FAQ´s - Functional Safety
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What is Functional Safety in drive technology?Functional safety ensures that a machine remains safe even if a technical failure occurs. In drive technology, this means the motor and its electronics must detect errors, react in a specific way and move to a "safe state." At Dunkermotoren, this is achieved through the dSafe series, which monitors and manages drive behavior automatically.
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Why is integrated safety better than external safety modules?Integrated safety, like that found in Dunkermotoren’s BG 75 dPro and BG 95 dPro motors, eliminates the need for external safety relays. This reduces wiring complexity, saves space in the control cabinet, and minimizes the risk of installation errors, ultimately lowering the total cost of ownership.
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What does "Safe Torque Off" (STO) do?STO is the most common safety function. It ensures that no power is sent to the motor that could generate torque. Dunkermotoren’s integrated STO is unique because it keeps the motor’s communication and logic alive during a stop, allowing for an immediate restart without needing to re-home the system.
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How do motors ensure safe human-robot collaboration?To work safely near people, motors use functions like Safely Limited Speed (SLS). Dunkermotoren drives can be configured to monitor their own velocity; if the motor exceeds a defined safe speed, it automatically triggers a safety reaction, protecting the operator from injury.
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Which international safety standards should I look for?A safe drive should comply with EN ISO 13849-1 and IEC 61800-5-2. Dunkermotoren products are certified by TÜV up to Performance Level d (PL d), ensuring they meet the high safety requirements of European and international machinery directives.
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Can safety signals be sent over a standard network cable?Yes. Using "Safe Communication," safety data is sent over the existing Fieldbus. Dunkermotoren supports FSoE (Fail Safe over EtherCAT) and PROFIsafe, allowing for seamless integration into your safety PLC without extra hard-wiring.
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How does a drive detect if its own sensors are failing?High-level safety requires "redundancy." Dunkermotoren uses a modular encoder system that compares two different feedback signals (e.g., incremental and absolute). If the signals don't match, the drive detects a fault and shuts down safely.
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Is Functional Safety necessary for AGVs and AMRs?Yes. Autonomous Mobile Robots (AGVs) must operate safely in shared spaces. Functions like Safe Limited Position (SLP) and SLS are critical here. Dunkermotoren’s dSafe motors are specifically designed for intralogistics to handle these dynamic safety requirements.
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How does "Safely Limited Speed" (SLS) prevent accidents in collaborative workspaces?The Technical Detail: SLS is a monitoring function that ensures a drive does not exceed a predefined speed limit. In Dunkermotoren’s dSafe motors, the internal controller continuously compares the actual speed from the encoder feedback against a safety threshold. If the limit is breached due to a control error or external force, the drive independently triggers a safe stop.
The Advantage: This is vital for "Setup Mode" or "Maintenance Mode," where operators must be near a moving machine. By using Dunkermotoren’s BG series with integrated SLS, you can eliminate expensive external speed monitors, ensuring the motor protects the operator without a complete power shutdown, which speeds up cycle times once the operator leaves the zone. -
What role does "Safe Brake Control" (SBC) play in preventing mechanical damage?Safe Brake Control (SBC) helps prevent mechanical damage by ensuring that brakes are applied safely, reliably, and only under the correct operating conditions.
In practice, SBC ensures that a holding or safety brake is engaged only after an axis has come to a standstill, which avoids shock loads and premature wear. On gravity loaded or vertical axes, SBC prevents uncontrolled movement during power loss or safety shutdowns, protecting both the load and the mechanical structure. In addition, controlled brake actuation and optional brake testing help reduce thermal stress and detect brake wear early, further supporting the long-term protection of mechanical components. -
How does "Safe Stop 1" (SS1) differ from a standard emergency stop?The Technical Detail: A stop with STO simply cuts power, which can cause a high-inertia load to coast dangerously for several seconds. SS1, as implemented in Dunkermotoren’s dSafe electronics, actively brakes the motor along a monitored ramp until it reaches a standstill, and only then activates Safe Torque Off (STO).
The Advantage: This "controlled stop" is much safer for high-speed applications. It ensures the motor stops in the shortest possible distance and time, reducing the "danger zone" footprint of your machine. Since Dunkermotoren handles the braking ramp internally, you don't need to program complex deceleration curves in your safety PLC. -
Why is Functional Safety the backbone of modern Intralogistics and AGVs?The Industry Layout: In warehouse automation, Autonomous Mobile Robots (AMRs) and AGVs move through high-traffic areas. To meet ISO 3691-4 standards, these vehicles must react to laser scanner data by slowing down or stopping safely.
The Dunkermotoren Solution: By using Dunkermotoren’s Hub Wheel Gearboxes or BG motors with FSoE (FailSafe over EtherCAT), the vehicle’s safety scanner can talk directly to the drive over the network. If an obstacle is detected, the drive executes a Safely Limited Speed or Safe Stop. This integration allows AGVs to be smaller and more agile because the "safety cabinet" is essentially built into the motor housing itself.