Inxpect Radar Safety System Integration with Siemens PLC and HMI

Integration of Inxpect Radar Safety System with Siemens PLC and HMI for Dynamic Zone Supervision and PROFIsafe Diagnostics.

Controls Engineer – Safety Systems Integration & Automation

Problem

Industrial safety systems often rely on static light curtains or laser scanners, which are limited in harsh or dusty environments. The goal was to implement a radar-based alternative that offers:

  • Reliable object detection in challenging conditions.

  • Seamless PROFIsafe communication with the PLC.

  • Real-time supervision and alarm visualization on the HMI.
    The challenge included configuring correct GSDML profiles, managing F-runtime safety blocks, and ensuring that PROFIsafe diagnostic data from the Inxpect controller was correctly processed by the PLC.

This project focused on integrating an Inxpect C201AB radar-based safety system with a Siemens PLC (S7-1500F) and WinCC HMI to create a fully functional, PROFIsafe-compliant safety monitoring setup. The objective was to configure, program, and validate a dynamic safety supervision environment capable of detecting presence in safety zones (DF1/DF2), diagnosing system faults, and dynamically visualizing and alarming safety states on the HMI.

Process

1. System Setup

  • Installed the Inxpect C201AB controller and paired it with two radar sensors.

  • Configured the system in Inxpect Safety Application, setting DF1 and DF2 detection zones and verifying CRC configurations.

  • Imported the GSDML 2.1.0 file into TIA Portal to establish the PROFIsafe connection.

2. PLC Programming

  • Created F-runtime safety blocks using LDiag_SafeRadarPD and FB_SafeRadarQS for diagnostics and zone handling.
    Debugged errors like “F-block called outside of F-runtime group” by correctly embedding safety FBs within the safety task structure.

  • Connected DF1/DF2 zone status and OSSD outputs to Siemens safety I/O addresses.

3. Diagnostics & Logic Integration

  • Developed a diagnostic layer for system health monitoring using SafetyInterfaceDiagOpMode01.

  • Created supervision logic to detect:

    • Communication faults (PROFIsafe disconnection)

    • CRC mismatches

    • Restart requirements

    • Zone activity

  • Implemented watchdog timers and fault logic for live safety supervision.

4. HMI Integration

  • Configured dynamic HMI alarms for radar states (DF1 active, DF2 active, fault, communication lost).

  • Built text lists and dynamic supervision indicators for operator feedback:

    • 0 = OK

    • 1 = Detection Field Active

    • 2 = Restart Required

    • 3 = Fault / Communication Error

5. Testing & Validation

  • Verified correct zone activation by walking into radar detection fields and monitoring live signal changes.

  • Simulated fault conditions (e.g., unplugging sensors) to test communication fault handling and dynamic alarm behavior.

  • Linked supervision outputs to HMI alarms for real-time fault reporting.

Prototype

The final prototype consisted of:

  • Inxpect C201AB Controller with dual radar sensors.

  • Siemens S7-1500F PLC programmed with safety and diagnostic logic.

  • WinCC HMI Panel displaying dynamic status, fault messages, and zone activations.

  • Fully wired communication between radar → controller → network switch → PLC → HMI.

Results

  • Achieved full PROFIsafe communication between the Inxpect radar system and Siemens PLC.

  • Enabled live detection zone monitoring (DF1/DF2) and automatic fault detection on the HMI.

  • Implemented dynamic supervision logic, allowing operators to see system states and alarms in real time.

  • System successfully responded to both detection and diagnostic events, validating its reliability for industrial safety use.

Impacts & Takeaways

  • Enhanced Safety: The radar system provided reliable detection in environments unsuitable for optical sensors.

  • Dynamic Monitoring: The supervision framework allowed instant visibility of radar states and health conditions.

  • Industry Readiness: The integration approach can be replicated across industrial robotics or autonomous vessel systems.

  • Technical Mastery: Developed advanced knowledge in PROFIsafe configuration, safety FB programming, and PLC-HMI interfacing.

  • Problem Solving: Overcame real-world integration challenges including safety FB conflicts, submodule mapping, and diagnostic linking.

Key Technologies Used

  • Siemens TIA Portal V17

  • Inxpect Safety Application (v2.1.0)

  • Siemens S7-1500F PLC

  • WinCC HMI (Comfort Panel)

  • PROFIsafe / PROFINET Communication

  • Ladder Logic and Structured Control Language (SCL)

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