Gyro Systems, a market leader in autonomous mobile robots (AMRs), has combined Beckhoff’s safety drive technology with PC-based control architecture to help a leading international semiconductor company in the United States deploy a highly efficient AMR system that meets international safety standards. Even in space-constrained environments, it enables automated handling of material carriers such as FOUPs and trays, significantly improving logistics efficiency and reducing the workload on personnel, thereby establishing a more flexible and competitive logistics foundation for smart semiconductor factories.
Gyro Systems specializes in autonomous mobile robots (AMRs) and automated material handling systems (AMHS). By leveraging years of project experience and technical expertise in smart logistics for the semiconductor industry, the company has earned recognition among tier 1 customers worldwide, including in Taiwan, the United States, and Japan. “When we began collaborating with internationally renowned semiconductor companies, equipment safety was no longer just a bonus – it had become a basic requirement for entering the market,” said Jacky Chen, director of sales at Gyro Systems. In the U.S. market in particular, customers have extremely strict safety requirements for AMRs. The equipment must comply with international safety standards such as ISO 3691-4 and ANSI/RIA R15.08, and it must undergo a comprehensive functional safety design and verification process before it can be introduced into a production environment.
TwinSAFE establishes a reliable functional safety architecture that allows these hurdles to be overcome.
To meet the stringent safety requirements for AMRs, Gyro Systems uses Beckhoff’s TwinSAFE functional safety technology to build a safety control architecture that complies with international standards. Through the Safe Motion feature, the system can implement safety mechanisms such as STO (Safe Torque Off) and SS1 (Safe Stop 1): in the event of a malfunction or emergency, motor torque output can be cut off immediately; when a controlled stop is required, the system decelerates along a preset ramp before coming to a stop, effectively reducing mechanical shock and improving operational safety.
“Sometimes the value of the wafers inside a FOUP is higher than that of the AMR itself.” Gyro Systems noted that a collision, dropped material, positioning error, or unexpected shutdown could result in significant material losses and even disrupt the operation of the entire semiconductor production line. Therefore, the functional safety mechanisms established by TwinSAFE can reduce the risk of unplanned downtime and ensure stable handling of high-value wafers and process materials.
Low-profile AMRs face space challenges: Compact drive technology overcomes space constraints
In a project with a well-known U.S. wafer design and manufacturing company, the AMR had to have a low-profile chassis to accommodate the pick-and-place height of the customer’s tray carriers. At the same time, the equipment also had to comply with international safety standards such as ISO and ANSI. In traditional architectures, motors typically require an additional safety encoder to enable safe speed monitoring, which poses a design challenge for AMRs, where space is already limited.
“Therefore, we had to find a solution that balances functional safety with a compact design, and the Beckhoff DC servo drive system was the best choice,” said Jacky Chen, director of sales at Gyro Systems. AMRs typically use 48 V DC onboard power, and Beckhoff’s 48 V DC servo motors feature an extremely compact design with an integrated absolute encoder. With One Cable Technology (OCT), motor power and encoder signals are combined in a single cable, simplifying wiring and reducing installation space to meet the mechanical requirements of low-profile AMRs.
PC-based control integrates Safe Motion to streamline AMR development
GYRO Systems also implemented a Beckhoff compact Industrial PC, using a single platform to integrate motion control, safety, sensors, and device communication. For semiconductor AMRs that need to integrate navigation systems, robotic arms, and sensors, this approach reduces system complexity and space requirements while maintaining the flexibility to connect with third-party devices.
“We also see strong potential in the modular advantages of Beckhoff EtherCAT I/O. “Since semiconductor customers often have different functional requirements for AMRs depending on their processes and applications, modular I/O reduces the need for hardware redesign and rewiring, helping accelerate system development. We also see potential to extend this approach to other AMR systems in the future,” said Kaichun Wu, manager of robotics software, Smart Robotics Business Unit at GYRO Systems.
Local technical support behind cross-border projects
“When working on overseas projects, the biggest concern is not encountering problems, but not having someone available to provide immediate support,” said Jacky Chen, director of sales at Gyro Systems. Gyro Systems knows how important global technical support is through first-hand experience. When an end customer had an urgent technical need, the Beckhoff Taiwan team immediately coordinated with their U.S. counterparts. The Beckhoff U.S. team then provided on-site support and successfully resolved the issue. For Gyro Systems, Beckhoff is not only a provider of control and drive technology; through its global technical service network, it has also become a key partner in driving international projects, ensuring the smooth deployment of equipment at plants around the world.
Building safer and more reliable smart material-handling systems for the semiconductor industry
From low-profile design and functional safety to control integration, GYRO Systems has successfully met the safety and reliability requirements of international semiconductor customers for material handling by using Beckhoff’s 48 V DC servo drives, TwinSAFE safety control, and PC-based control architecture. As semiconductor manufacturing continues to evolve toward smart manufacturing, AMRs are responsible not only for material-handling tasks but also for the safe transport of high-value wafers and process materials. In the future, Gyro Systems will continue to integrate Beckhoff’s open automation technology to develop smart material-handling solutions that combine functional safety, stability, and flexibility.