Modern Sa Safety Systems and and Adv Advanced Flui Fluid Power - - PowerPoint PPT Presentation
Modern Sa Safety Systems and and Adv Advanced Flui Fluid Power Solu Solutions Chris Brogli Global VP of Safety Business Development ROSS Controls TUV FS Expert ID#213/13 Phone: 1-859-595-9630 Email: chris.Brogli@rosscontrols.com ROSS
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Chris Brogli Global VP of Safety Business Development ROSS Controls TUV FS Expert ID#213/13 Phone: 1-859-595-9630 Email: chris.Brogli@rosscontrols.com
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This competition is driving technology advancement across the globe.
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1900-2000 Gasoline only Early 2000’s Hybrid 2010’s Electric Today Self-driving Early 1900’s-1990’s Wired 1990’s Bag Early 2000’s Flip Mid 2000’s Smart Today Apple Watch
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Safety Technology Advancements
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Let’s take a look at how these advancements are affecting electrical safety solutions!
Detection
Machine safety is evolving with new technologies that improve safety and productivity.
security control systems
functions
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Physically Independent
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Physically Combined
ROSS Controls In 2009 safety ty re rela lays were re 70% of the safety logic gic to today 70% or the mark rket t is safety ty controllers & safety PLC’s. This allows for better control & monitoring of the safety system.
Relays Controllers & PLC’s Relays Controllers & PLC’s
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relays to turn off standard solenoids.
center solenoids
valves
with standard controls was good enough.
solenoids (SR)
ball valves
safety controllers & safety PLC’s
safety solenoids
valves
Fluid power solutions are evolving the same way electrical products did 10 to 15 years ago.
control systems
fluid power safety solutions
systems
ROSS Controls Our older products were self monitored but were large and expensive. Our new products are smaller and match the electrical safety transition.
Old Products with Internal Monitoring Contemporary Products with External Monitoring Current Products with Electrical Internal Monitoring
Pneumatic safety solutions are evolving with solutions that make them easier to integrate.
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ISO 138 13849 49-1 1 – 201 2015 5 required ed user sers s to inclu clude fluid id power er sa safet ety y as s part of the sa safet ety y co control l sys ystem em.
Most companies ignored fluid power safety until the ISO13849 standard changed in 2015.
ROSS Controls Let’s take a look at standards of today to understand the requirements.
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OSHA Machine Safety 1910.xxx Machine Safety - General Safety Requirements ANSI B11.0 Machine Safety - Principles for Risk Assessment ANSI/RIA TR15.306 Machine Safety - Selection of Programmable Electronic Systems (PES/PLC) for Machine Tools ANSI B11.19 Electrical equipment of machines ANSI/NFPA 79 European Machine Directive 2006/42/EC Machine Safety - Basic concepts EN/ISO 12100 Machine Safety - Principles for Risk Assessment EN/ISO 14121 Machine Safety - safety- related parts of control systems EN/ISO 13849-1 Pneumatic Safety – EN/ISO 4414 Hydraulic Safety – EN/ISO 4413 Machine Safety - Functional safety of EEPES control systems IEC 62061 Pneumatic Safety – ANSI B11.0 Hydraulic Safety – ANSI B11.0 Machine Safety - Electrical equipment of machines IEC 60204-1
Notice that there are specific standard for Fluid Power Safety.
General Safety Requirements Risk Assessment Requirements Design Requirements Fluid Power Requirements Electrical Requirements
ROSS Controls ISO12100 & ANSIB11.0 outline the basic requirements for risk assessment & risk reduction.
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Risk Assessment
The top part of ISO12100 and ANSI B11.0 deal with assessing risk.
The ISO12100 and ANSIB11.0 methodologies provide a systematic approach as shown in the flow chart below.
Determine the Limits Identify the Hazards Estimate the Risk Evaluate the Risk
Assessment
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There are specific requirements for the use, implementation and utilization of hydraulic and pneumatic components in control systems according to ISO13849-1.
ISO4414 & ISO4413 say that hydraulics & pneumatics must be considered and identified risk must be eliminated or reduced.
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We need to think about powered and unpowered hazards, like falling loads! This means that we need to think about…
ROSS Controls There are a number of risk estimation methods that yield varying results. ISO13849 has become one of the most widely used methodologies.
The Global Leader in Fluid Power Safety Solutions TR13.306 Methodology
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The reason that many companies have adopted ISO13849 is because it addresses all technologies and provides a more holistic approach to machine safety.
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EN 954-1 EN ISO 13849-1
Electrical Control Circuits Control circuits all technologies :
Safety Categories B, 1, 2, 3 & 4 Performance Levels PLa to PLe Safety provided by the structure
Safety provided by:
categories)
causes of failure (CCF) Draw a diagram (schematic) Draw a diagram and verification of PL Does PL(achieved) = PLr (required) ? Not just electrical anymore! EN954-1 was withdrawn in
Categories exist today is as a part of ISO13849. ISO13849 adds some important factors that must be considered in the selection design and implementation of safety solutions
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If a machine safety solution is required it must be designed to meet a standard to prove compliance to the machinery directive.
Since EN954-1 was withdrawn in December of 2011 and IEC62061 only deals with electrical, electronic and programmable electronic systems. ISO13849-1 has become the most commonly used machine safety standard because it addresses all technologies including fluid power.
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If fluid power hazards are moderate, serious or catastrophic the safety solution has to meet PLc, PLd or PLe.
ANSI B11.0 & EN13736 provide performance requirements based on pressure & force.
ROSS Controls Once we are done with the assessment we need to determine how to reduce
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The bottom part of ISO12100 and ANSI B11.0 deal with risk reduction.
Reduction by Design Reduction by Guarding Reduction by Safeguards Reduction by Information & PPE
Risk Reduction
Reduction by Elimination
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Th The ones circle led in re red apply ly to to fluid id power r safety as well.
The follo lowin ing slides will l show how these are re used in modern rn safety ty solutio ions.
Elimination Safeguard Safeguard Safeguard Parameterized Safeguards Safeguard
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Pneumatic Safety Devices & Solutions
control of actuators
stopping of actuators
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Elimination LOTO is used for maintenance, repairs and servicing of machinery.
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positions (ON and OFF)
has dissipated after initiating lock out process.
The LOTO/energy isolation device is not an E-Stop device, but it may serve as the primary isolation device in an emergency.
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position
positions (ON and OFF)
energy has dissipated after initiating lock out process.
Hydraulic LOTO/energy isolation is similar to pneumatic LOTO but you can’t exhaust hydraulic fluid to atmosphere. You bleed it back to tank.
Positive OFF
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Safety Input Devices Safety Logic Devices Safety Output Devices
Complete Safety Function
When we do a risk and identify the risk level we need to design our safety solution to meet the Required Performance Level.
Safeguard
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Safe Isolation
You have to be very careful with safe isolation solutions because they remove air or hydraulic energy. This could cause cylinders to shift/move (Especially in vertical applications).
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Safe Direction is a common safety related function/parameter that is used with drives and servos. We can accomplish that today by the use of Safe-return valves. Safe Direction/Safe Return
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Safe Stop/Safe Holding Safe Stop is a common safety related function/paramets that is used with drives and servos. We can accomplish that today by the use of Safe-load-holding valves.
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Ball valves are not tamper resistant and can be locked in the
indication that energy has been dissipated. They are also not easily identifiable. A single failure of a standard single-acting solenoid can lead to the loss of the safety function and these valves do not have sensing to detect when a failure occurs. A single failure of a standard double-acting solenoid can lead to the loss of the safety function and these valves do not have sensing to detect when a failure occurs.
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Extend Retract
2 4 3 5 1
Broken spring = Unable to obtain center position
De-energized valve caused table to extend If using the retract button, the safety mat would cause the table to extend
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Transfer press line part removal
Operator removes part from conveyor A Part is placed on rack C Fork trucks remove full racks, load empty racks
Crushing/Shearing Hazard
Motionless
2 3 1
Rotating
2 3 1
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Sma mall Ma Machines
at I/O device (LED’s)
(Program change) Machine safety connectivity is evolving with new technologies that improve reliability and facilitate continuous improvement thru enhanced diagnostics and improved flexibility.
Workcells & & Sma mall Lines Continuous Lines
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In the future we will see valves that are connected via safety networks with no hard-wired connections.
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The result is smart and connected solutions that reduce wiring time and enhance diagnostics and improve reliability.
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I/O O Li Link nk and nd Ethe herNet et ba based Safet ety are 2 2 pr prot
ls tha hat are be being tested ed.
Both solutions would use quick disconnects, LED’s and smart monitoring to provide system status and system health feedback.
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These integrated solutions of for small and large lines and workcells that are made up of multiple stations. These machine utilize modular zone control and a combination of risk reduction techniques that include fluid- power safety, motion and servo safety utilizing a varieity of safety input devices.
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Let’s break this down to the cell/station level and look at wiring costs.
@ $35 per hour = $1300 per station
I/O block
– 25 point @ 5 minutes
station
@ 5 minutes
station
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Common Solutions Include:
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Solutions
Weld Station Rivet Station
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Best t in class companie ies are re using these advanced te technolo logie ies to to improve safety and producti tivi vity.
The Aberdeen study showed that the safest companies are also the most productive!
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industry!
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– Based on ANSI B11.0 2015 requirements and ISO4413 and ISO4414
– Safety Related Parts of the Control System according to ISO13849-1