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  4. Safety PLC Integrated into Robot Controller - New product: Safety Software PLC Eliminates the Need for External Safety PLCs and Significantly Reduces System Costs

Safety PLC Integrated into Robot Controller - New product: Safety Software PLC Eliminates the Need for External Safety PLCs and Significantly Reduces System Costs

FANUC announces the launch of its new Safety Software PLC for the latest R-50iA robot controller. Building on the Software PLC functionality already available on the R-50iA, FANUC has now added Safety Software PLC capability, enabling safety control functions to be implemented directly within the robot controller without requiring additional hardware. External hardware safety PLCs, which have traditionally been required to manage safety signals, are no longer necessary, resulting in substantial reductions in system costs.

Key Features of Safety Software PLC

Significant Reduction in System Costs

  • Safety Software PLC is implemented as software within the R-50iA robot controller and conforms to the requirements of ISO 13849-1 Performance Level e (PL e). It enables safety sequence control for automation systems without requiring a separate hardware safety PLC.
  • The R-50iA’s Software PLC is based on CODESYS, supports six programming languages and IEC 61131-3 compliant, and is widely used for machine control applications. FANUC has further enhanced this functionality to provide integrated Safety Software PLC capability within the robot controller.
  • In addition, the Software PLC’s browser-based HMI functionality allows process control screens to be displayed on the robot teach pendant or on commercially available low-cost tablets. Users can monitor safety signals and operate the system directly from these interfaces, reducing not only PLC-related costs but also the cost of dedicated operator panels.
  • The R-50iA can also connect directly to safety devices via Safety EtherNet/IP, helping simplify wiring and further reduce installation costs.

Integrated Control of Robot Safety Zones

  • In applications where humans and robots share the same workspace, safety controls are required to adjust robot operating areas and speeds based on human presence. Because Safety Software PLC is integrated within the R-50iA controller, it can be seamlessly combined with FANUC’s Dual Check Safety (DCS) technology, which monitors robot operating zones and speeds.
  • Safety Soft PLC can directly control DCS-defined safety zones, allowing complex safety sequence control related to robot motion areas and operating speeds to be implemented easily and efficiently.

Support for Virtual Commissioning

  • FANUC’s ROBOGUIDE simulation software now supports simulation of Safety Software PLC programs in addition to robot programs. This allows users to simulate the entire robot system, including safety devices, on a single PC before deployment.
  • Previously, Safety PLC sequence control programs could not be verified without physical hardware. With Safety Soft PLC, users can develop and verify both robot and safety control programs in advance through virtual commissioning, reducing engineering effort and shortening system build, installation, and startup times.

FANUC will showcase and demonstrate the Safety Software PLC for the R-50iA controller at JIMTOF 2026 (Japan International Machine Tool Fair), which will be held at Tokyo Big Sight beginning October 26, 2026. Through significant system cost reductions and advanced virtual commissioning capabilities, Safety Software PLC contributes to more efficient and cost-effective factory automation solutions.

Shipments start: January 2027

Configuration of the Safety Software PLC
Configuration of the Safety Software PLC

Safety Zone Control through Integration of Dual Check Safety and Safety Soft PLC
Safety Zone Control through Integration of Dual Check Safety and Safety Soft PLC

（October 2026）