Safety Solutions: Protect What Matters Most with TwinSAFE
- Christopher Woller
- Jul 16
- 3 min read
In a recent Webinar Wednesday session, Beckhoff USA’s Chris Woller guided viewers through the fundamentals and future of functional safety using TwinSAFE
Whether you're an OEM designing scalable machinery or a plant engineer maintaining complex systems, this webinar offered critical insights into how Beckhoff’s integrated safety technology empowers safe, modular, and efficient automation.
Download the full recorded webinar here:
The importance of machine safety
Safety in industrial automation is more than a compliance requirement—it’s a legal and ethical obligation. Regulations such as those defined by OSHA in the U.S. and the Machinery Directive in the EU ensure that industrial systems are designed to minimize risk to human life. Definitions from ISO 61508 and ANSI B11.0 clarify what “safe” means: freedom from unacceptable or likely harm.
TwinSAFE helps meet these global standards by providing a comprehensive solution that is flexible, scalable, and fully integrated with standard automation technology. From emergency stops to complex motion functions, Beckhoff’s safety technology covers the full spectrum of applications.
The foundation: core Beckhoff technologies
Beckhoff’s machine safety offering is built on a foundation of three key technologies:
EtherCAT, the real-time Ethernet fieldbus
TwinCAT, the modular engineering and runtime software
Modular hardware, including I/O and drives with built-in safety logic
Together, these enable the seamless implementation of Safety over EtherCAT (FSoE)—a SIL 3-rated protocol developed by Beckhoff and now adopted globally by over 60 manufacturers.
Architectures that fit every application
TwinSAFE supports a wide range of safety architectures, from compact standalone systems to expansive, highly coordinated networks. For simpler applications, safety functions can be fully self-contained within devices, requiring no further integration. These systems are ideal for machines with limited I/O or fixed configurations. More integrated environments benefit from compact or centralized architectures, where devices share data over EtherCAT, and a central controller manages all safety logic. This is especially effective for large-scale operations requiring synchronized safety responses across multiple zones or components.
What truly sets TwinSAFE apart, though, is its support for fully distributed architectures. Because logic is embedded in every safety device, each part of a machine can handle its own safety functions locally, enabling scalable, modular designs. OEMs can preconfigure safety logic for individual modules, simplifying on-site installation and customization. Whether adapting to new customer requirements or complying with regional safety standards, TwinSAFE’s dynamic architecture ensures flexibility without complexity.
TwinSAFE SC and cost-effective safety
A standout segment of the webinar covered TwinSAFE SC (Single Channel). This technology allows for certified safety implementations using standard I/O terminals (with a special firmware) and sensors. By leveraging redundancy and diverse technologies (e.g., pairing an RTD and a thermocouple), users can achieve SIL2/PLd levels of safety at a lower cost.
Over 25 TwinSAFE SC-compatible signal types are available today, with options suited even for environments that require intrinsically safe hardware.
Integrated motion safety
Beckhoff’s diverse motion and drive technology components also benefit from TwinSAFE. With 17 certified safety functions available—and more in development—users can implement advanced features like Safe Limited Speed and Safe Torque Off across Beckhoff’s drive systems, enabling safer and more productive motion control.
Looking to the future
The next evolution in machine safety is already underway: Beckhoff is bringing safety logic directly onto industrial PCs. This shift will deliver faster performance, more memory, and expanded development tools for advanced applications, including simulation, navigation, and complex motion coordination.
Built for what's next
TwinSAFE is designed to grow with your needs—whether you're building smarter machines, expanding global operations, or simply increasing safety standards. Its integrated architecture and modular design make it a forward-thinking investment in both protection and productivity.
Ready to elevate your machine safety strategy with scalable, integrated solutions from TwinSAFE? Contact your local Beckhoff sales engineer today!
And don't forget to check out our upcoming and on-demand webinars to stay current on the latest automation innovations from Beckhoff.
Chris Woller is a Safety Product Manager at Beckhoff Automation LLC
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