The KEBA KeSafe D3 is a highly integrated, freely programmable safety PLC that sets the standard for modern machine and robot safety. As an integral part of the KeDrive D3 control and drive system, it provides a decentralized, scalable safety solution that guarantees the safe operation of machinery and robots in compliance with the most stringent international standards and regulations. Its innovative architecture simplifies system design by combining safety logic, drive monitoring, and comprehensive safety I/O into a single, compact device.

Uncompromising Safety Standards

The KeSafe D3 meets the highest safety requirements for demanding industrial applications. It is certified to Category 4, PL e according to EN ISO 13849-1 and SIL 3 according to EN 62061 and EN 61508. This level of certification makes it suitable for a wide range of safety-critical tasks, from simple safe logic and safe single-axis functions up to complex, extended safety functions for robotics. The integrated safety controller is designed to enable human-robot collaboration (HRC) in accordance with ISO TS 15066.

Flexible and Scalable Safety I/O

As the core of the safety solution, the KeDrive D3-DU 3x5 module provides a substantial amount of fail-safe onboard I/O, including 20 safe digital inputs, 8 safe digital outputs (0.5A), 2 safe digital outputs (2A), and 2 safe relay outputs. This generous configuration eliminates the need for many external safety modules. For applications requiring decentralized safety, the system can be easily expanded via FSoE (Fail Safe over EtherCAT) to connect remote safety modules, providing maximum flexibility in system layout.

High-Performance Safety for Robotics

The KeSafe D3 is uniquely equipped to handle the complex safety demands of modern robotics. Its safe motion monitoring capabilities support comprehensive robot safety functions, including safe Cartesian speed limits, safe monitoring of tools, and safe cell concepts. The system is kinematics-independent and supports complex robotics applications with up to 12 axes. This ensures that robots can operate safely in collaborative and industrial settings, seamlessly integrating with the broader automation environment.

Intuitive Programming with KeStudio SafeEdit

Developing safety applications is streamlined with KeStudio SafeEdit, an integrated graphical programming tool within the KEBA engineering suite. This powerful tool allows for free programming using certified, reusable, and individually combinable function blocks for logic, motion, and robotics. This abstracted block-based approach significantly reduces engineering time and complexity compared to traditional safety programming. The tool also includes comprehensive diagnostics and validation support, ensuring that safety applications are correctly implemented and compliant from the start.

Applications

The KEBA KeSafe D3 is ideally suited for a wide range of applications requiring integrated, high-performance safety:

• Industrial robotics and collaborative robots (cobots)
• CNC machine tools and metal forming machinery
• Packaging machinery and material handling systems
• Complex, multi-axis special-purpose machinery
• Applications requiring functional safety up to SIL3/PL e

Technical Specifications