Whilst every effort is made to ensure technical accuracy of the information supplied on iceweb.com.au, Keyfleet Pty Ltd and its employees accept no liability for any loss or damage caused by error or omission from the data supplied. Users should make and rely on their own independent inquiries. By accessing the site users accept this condition. Should you note any error/omission or an article offends please do not ignore it, contact the webmaster and we will review, rectify and remove as necessary.
Proudly Sponsored by
Have
a question on or need to purchase Manufacturing or Safety Automation? Our
Sponsors Pilz
are Experts in this area!
Contact them here.
For the latest information on safe engineering standards and legislation, sign up for the Pilz free newsletter.
Is your machinery and work equipment safe enough? - To help manufacturing companies prevent accidents and remain within the law, Did you know that Pilz offers a Plant Assessment service?
1.10
Emergency
Stops – Make sure yours Comply - As Emergency Stops are
the last line of defence in machine safety it is imperative that they operate
correctly when/if required. So what are some of the things you can do to ensure
the E-Stop will work when called upon? This technical paper takes a detailed
look at the different types of Emergency Stop Devices and what you can do to
ensure their effectiveness.
2.10
Packaging
for experts - Safe, Flexible Drive Technology for Surimi, Sandwiches etc -
Whether it’s a pudding in a glass, with or without outer packaging, fresh
herbs in a plastic tray, or the spoon in an ice cream tub – different products
require different packaging solutions. In this case the quality of the packaging
is just as important as the productivity and multifunctionality of the actual
packaging line. Packaging lines must also satisfy the highest requirements in
terms of productivity, flexibility and reliability. Flexible drive technology
guarantees that foodstuffs are packaged quickly, precisely and carefully.
11.09
Metal
Lathes - Can they be made Safe? -
Frank Schrever
-
How can these risks be minimised? A simple interlocked
chuck guard connected via a Category 4 control system in accordance with
AS4024.1 that prevents the machine from starting while open, will remove or
significantly reduce most lathe safety risks.
11.09
Concepts
for Secure Safety Gate Monitoring -The Right Sensor for every
Requirement - Increasing automation in mechanical
engineering means that the demands on machine safety are also rising. Aspects
of process safety, availability and cost-effectiveness must all be reconciled.
Safety guards or gates ensure that operating personnel are
protected against flying metal swarf or hazardous movements on plant and machinery.
Their position can be monitored by a wide range of safety switches available on
the market, which take into account not only
safety-related aspects but economic considerations too. The switch you use will
depend partly on the machine and partly on the
safety-related requirements.
6.09
Seize
Control of Safety and Productivity -
4.09
As
Tough As They Come - Extremely Robust Control System Provides Safety Underground
- A control system is normally found inside a control cabinet, where it is
well protected from all types of environmental influences. But control systems
can also be installed on mobile machinery, where they may be subjected to
rigorous shaking. Shock and vibration must not be allowed to compromise the safe
function of the control system in any way. Consequently, the Pilz programmable
control systems used in mining on roadheaders, to safely monitor the spray
function, need to be especially robust.
Doing Safety the “Right Way” Lifts Productivity Too - Are safety and productivity incompatible? If safety is an afterthought, absolutely, but safetymeasures that are worked into the very design of manufacturing plant actually boost productivity, says Pilz managing director Frank Schrever.
Machinery Safety and the need to Save Money - It can be a false economy - or potentially dangerous - to try saving money on safety systems, yet careful design can reap rewards. Given the state of the economy, it is understandable that everyone has to be more careful with their budgets than ever before. But engineers should beware of trying to save money by buying cheaper safety-related products, as it could cost them dear in the long run.
Monitored at all times - Drive-integrated safety opens up new horizons - Safe drive functions have made their mark on standards, products and applications and may now be considered as state of the art. They are part of the functional safety plant and machinery and, as measures that boost productivity; they are increasingly gaining ground in the market.
Safety in each phase of the flight - Pilz ensures flight safety on the Sky Roller - Speed and thrills are what’s required of the attractions on offer at funfairs and amusement parks. On today’s modern fairground attractions, riders are catapulted through extreme radii or carried along in hair-raising positions; these attractions need to perform their service reliably and virtually failure-free. Where the laws of gravity appear to be temporarily suspended, as on the Sky Roller, a Pilz programmable safety system is there in the background, making sure that nothing gets out of hand.
The True Value of Free Technical Support - Technical support enables design and maintenance engineers to save time and money in both new projects and existing plant.
A Safe, Clean Business - Pilz Safety System Monitors an Exhaust Purification Plant - Systems for thermal exhaust purification are subject to the furnace regulations. The safety of such plants presents a particular challenge for automation technology. A multifunctional, modular safety system can not only monitor the safety functions in exhaust purification systems, but can also enable manufacturers to implement flexible burner control systems in such plants.
The Golden Rules of Risk Assessment - Frank Schrever - At its worst, the risk assessment is a bureaucratic time-waster that does nothing to make workplaces safer. On the other hand, following five golden rules mean risk assessments can be both functional and lifesaving. From Pilz and Manufacturers Monthly.
Single contactors for Category 3? Can faults be excluded? - Can single contactors be used for safety control category 3 if the contactor is over-rated?
The CE Mark – What does it really mean? - The CE mark can be found on pretty much any electrical appliance in the home. Turn your laptop computer over and there will be a CE mark there somewhere, usually mixed in with other markings. Imported machinery can also be found to have a CE mark. So what exactly does a CE mark mean? Is the appliance or piece of machinery safe due to having a CE mark? Not necessarily.
Replacement for EN 954-1: standard EN ISO 13849-1 is harmonised! - EN ISO 13849-1, as the successor to EN 954-1, is to become the main standard for the design of safety-related control systems in the "machinery safety" sector (the only dissenters were Great Britain, USA and Japan). The new standard was published in November 2006; It was listed as a harmonised standard under the European Machinery Directive in May 2007. There will be a three-year transition period, expiring November 2009, during which the standard EN 954-1 can continue to be used in parallel. This article covers; Status of standardisation, the main reasons for revising EN 954-1, what will change and how to reach your goal in six steps.
Functional safety with EN IEC 62061 and EN ISO 13849-1 - Standards and norms have a tremendous influence on safe automation. EN ISO 13849-1 - the successor to EN 954-1- have been ratified since November 2006. EN IEC 62061 can also be applied when considering functional safety on control systems. To help you get to grips with this important subject Pilz have developed a poster, on which the procedure for applying both standards is shown in parallel. As well as explaining the key terms and abbreviations, the poster shows the scopes of the standards and the relevant mathematical formulas. The A1 poster is currently available in German and English. You can order the standards poster via Pilz Marketing Department at the following Contact.
Standards
for Electrical Safety - The following standards are some
of the most important for machine electrical safety:
- EN
60204: Safety of machinery - Electrical equipment of machines
- EN 60947-5: Low voltage control gear
-
NFPA 79: Electrical Standard for Industrial Machinery
Standards
for Functional Safety - Attention
planners, constructors and users - here's where to find out more about the
functional safety standards - As the causes of hazards and therefore the
technical measures needed to avoid them can vary greatly, a distinction is made
between different types of safety, e.g. by stating the cause of potential
hazards. For example we talk about "functional safety" when safety
depends on the correct function of an electrical (E), electronic (E) and
programmable electronic (PE) system (in short: E/E/PE systems). The
following standards are some of the most important in this area:
- EN ISO 13849: Safety of machinery - Safety-related parts
of control systems
- EN/IEC 62061: Safety of machinery - Functional safety of
safety-related electrical, electronic and programmable electronic control
systems
- EN/IEC 61508: Functional safety of safety-related
electrical/electronic/programmable electronic systems
- EN/IEC 61511: Functional safety - Safety instrumented
systems for the process industry sector
- EN 954: Safety of machinery - Safety-related parts of
control systems
Bypassing Safely - Quite often the question is asked "How do we gain access into a machine to make adjustments, clear jams, perform maintenance etc., while the machine is running, and do it safely?”. Usually people just turn the safety system off (bypass) which is unacceptable by law. Frequently, a simple key switch is used to just bypass a safety gate. The problem with this solution is that the key can be left in the switch and the machine will run with the safety gate open all the time, which is unsafe. The key itself may not be safe and, anyway, it depends on human behaviour, thus it is an "administrative control”, which is near the bottom of the hierarchy of risk control. A tongue switch on a safety gate could be bypassed simply by using a spare tongue, carried in an operator’s pocket (a very common problem)!
Emergency Stops - Make Sure Yours Comply - As Emergency Stops are the last line of defence in machine safety it is imperative that they operate correctly when/if required. So what are some of the things you can do to ensure the E-Stop will work when called upon? This article takes a detailed look at the different types of Emergency Stop Devices and what you can do to ensure their effectiveness.
Preventing the Needless New Year Death Toll with Safety During Shutdowns - Death seems almost inevitable in the first few days of the New Year. WorkSafe Victoria statistics show at least one Victorian has died at work in the first week of January for the last five years. And tragedy strikes early in manufacturing's shutdown period too. Last year, nearly a quarter of the state's deaths at work happened in November and December. Now, heading towards Christmas once again, the authority has launched a campaign to attack the season's killer hazards: those associated with maintenance, repair, installation, servicing, and cleaning of machines (MRISC).
PAScal Safety Calculator - Reach your Goal with Ease - Pilz have developed a software tool so that it's child's play for you to define the safety level of plant and machinery. With the Safety Calculator you have a tool that makes it much easier for you to implement the systematic procedure in compliance with the new standards, without having to study the maths behind the standards.
Examining Robot Safety Standard- Roberta Nelson Shea - Pilz Automation Safety L.P.ANSI R15.06-1999 is the accepted American National Standards Institute standard covering safety requirements for industrial robots and robot systems. Speaking of safety, it’s safe to say that many end users or systems integrators simply assume that any new robots or systems automatically meet this standard, when in reality, regularly reviewing how the standard applies to your manufacturing operation can be very beneficial, even in non-robotic applications.
Make
Existing Cells Leaner and Safer
- Tina Hull - Pilz Automation Safety
L.P. - With numerous multi-robot cells in use, a company wanted to
increase existing robotic cell efficiency, making their systems more 'lean,' but
with no compromise in safety. The company would only proceed if the new setup
improved overall production uptime, was cost justifiable, and reduced the number
of steps for troubleshooting. The company chose a typical cell to examine.
Inputs included safety devices such as e-stops, safety gates, light curtains,
area scanners, pressure mats, pushbuttons, and sensors. Outputs powered
actuators, such as contactors, valves, robots, and drives.Common safety issues
were overlapping robot zones, continuous access for operators to load and unload
parts, safe access for maintenance teams, and the need to keep other equipment
running if one component became inoperative.
When
did you last inspect your safety light curtains? - Companies using light
curtains to safeguard machinery often do not appreciate the implications of the
regulatory requirement for inspections.
How functional safety helps to save lives -In this article Ron Bell explains functional safety and looks ahead to the revision of the IEC 61508standard that is due for publication in 2010.This article by Jeanne Erdmann was first published in the January 2008 edition of the IEC's E-TECH. http://www.iec.ch
Changes to European categories of safety control will come to Australia in due course - The basis of AS 4024-1501 safety related parts of control systems defines categories of control system design which become more fault resistant as the risk increases. This is changing in Europe with the adoption of EN-ISO 13849-2006, which replaces the categories defined in EN 954-1 (which is AS 4024-1501) with Performance Levels and will be fully adopted in Europe by end of November 2009.
Risk assessment still vital under new Victorian regulations - The new Victorian Occupational Health and Safety Regulations are designed to simplify safety but, in the case of risk assessments, their release has caused real confusion. From safetysolutions.net.au.
Not all e-stops are equal before the law – how to be sure yours comply - Because emergency stop devices or “e-stops” are everywhere, they tend to be taken for granted but the law takes them very seriously as the last line of defence in machine safety-Australian Standard 4024 describes an emergency stop as “a device which, regardless of the power source, e.g. electrical pneumatic or hydraulic, requires deliberate action to bring a machine to rest when danger is recognised”. Pilz Safe Automation's Frank Schrever explains the basics of how the Plant Regulations and the Australian Standard for safeguarding of machinery apply to emergency stop devices. From ferret.com.au.
SafetyBUS
p - The safe, open bus system- This is the first open, safe bus system to have been
approved by BG to category 4 in accordance with EN 954-1, EN 60204, EN 62061 and
by TÜV to AK 6 in accordance with DIN V 19 250, SIL 3 in accordance with EN IEC
61508 and NFPA 79. This guarantees a wide application area for safety
applications, from which users in plant and machine engineering as well as the
automotive industry can benefit.
Pilz
Safety PLC delivers uncompromising safety at new Darwin fuel terminal -With
up to 113 million litres of highly flammable fuels on site, the new Darwin
Industry Fuel Terminal's operators selected a highly specified Pilz Programmable
Safety System to oversee a very basic yet critical device: the emergency stop.
Pig tamed: Pilz safety system monitors 119 wine paths at Wolf Blass - A silicone pig sweeps through the lines at Wolf Blass, entering a ‘key station’ where winery staff must choose one of 119 paths. When it comes to safety, nothing has been left to chance – each path is safeguarded with a Pilz safety switch and the entire battery of switches is monitored by a Pilz Programmable Safety System (PSS).
Pilz PSS tame synchrotron’s silent hazards travelling at the speed of light - A safety challenge like no other in Australia. The newest and biggest piece of scientific equipment built here is just that - the Australian Synchrotron shoots electrons around its 216 metre circumference in just 720.5 nano seconds.
Safeguards at Australia's nuclear reactor world's best -when the world's most brilliant scientists use a new Australian Nuclear Science and Technology Organisation (ANSTO) experimental facility, they will be protected from radiation exposure by a meticulously designed network of Pilz Programmable Safety Systems (PSS).
Much more than guarding, safety is all in the design- An article by Frank Schrever of Pilz
1.10
Safety
Blows the Wind - Wind turbines fall under the scope of
the Machinery Directive - The revised version of the Machinery Directive
2006/42/EC comes into force on 29.12.2009. Even wind turbine manufacturers will
be required to deal with the new Machinery Directive because, by definition, a
wind turbine is a functional machine, and as such it falls within the scope of
the Machinery Directive.
AS4024 vs. AS61508 - Just as Australian industry comes to grips with safety standard AS4024, a newer, more complex, international and now also an Australian standard is gaining wider usage.
Productive safety - Only a safety system that enhances a line’s productivity is truly safe, according to Pilz Safe Automation. From Ferret.com.au.
Why everyone’s talking about safety - Occupational health and safety (OHS) seems to be on the lips of every engineer around the world today, and for good reason – the sheer number of work related deaths is still shocking at an estimated 2,256,335 workers per year. The annual injury rate must be in the hundreds of millions.
Laws, Standards and Approvals: Exploring the compliance jungle- When a machine is said to be “approved” or meets a particular design standard, sometimes the claim is misleading or irrelevant, but may actually hint at a legal necessity. From ferret.com.au.
Software and Firmware Based Safety Controllers By Tina Hull, Application Engineer, Pilz Automation Safety L.P.
Guide
to Programmable Safety Systems - This is a large
download in excess of 5Meg but it is worth the wait! This guide
covers:
- Programmable Electronic Systems in Safety-related
Applications
- Programmable Safety Systems: Concept
- Programmable Safety Systems: Hardware
- Programmable Safety Systems: Software
- Programmable Safety Systems: Selective
Shutdown
- Programmable Safety Systems in Conventional
Fieldbus Systems
- SafetyBUS p® Safe Bus System
- PSS®/SafetyBUS p® Applications
This A5-sized book runs to more than 200 pages and
will be of interest to engineers and managers concerned with the safety
of machinery and processes. Pilz has prepared the guide in response to
the growing importance of electrical, electronic, and programmable
electronic safety-related systems, and the increasing expectation of
executive bodies requiring companies to comply with the principles and
procedures of IEC 61508 (the series of standards for the functional
safety of E/E/PES safety-related systems). It is thought that there is
no other comparable publication that covers the topic in such detail,
providing theoretical and practical advice and guidance on how to comply
with the relevant legislation.
Guide to Machinery Safety - Now in its sixth edition, the Pilz 'Guide to Machinery Safety' is still remarkably popular among machinery specifiers, machine designers, electrical designers, maintenance engineers and safety managers.
This excellent guide
covers:
- Regulations for New Machinery
- Provision and Use of Work Equipment
- Regulations 1998
- European Harmonised Standards
- Risk Assessment
- Machinery Protection Devices
- Programmable Safety Systems
- Safe Networking
- Case Studies
1.10
Safety
Compendium - For the application of functional safety
standards - The primary purpose of safety technology on and in machinery is to
protect people from potential hazards. At the same time it protects the
environment and the actual machine from harm.The new safety compendium is aimed
at all those in mechanical engineering who deal with the issue of functional
safety and all its associated aspects. The compendium is intended as an
orientation guide for the application of functional safety standards. View the
compendium for free here.
EXCELLENT LINKS FROM Pilz UK - Also have a look at their download page for additional technical information
Looking for more information? Contact Pilz Australia
Standards
Guide:
Common Machine Safety Standards, Terms, Violations: Terms you need to know -
Understanding machine safety standards and terms remains a challenging first
step to spotting and reducing risks and increasing profitability. Sources for
help are many. Standards organizations covering machine safety include American
National Standards Institute (ANSI), National Fire Protection Association
(NFPA), Robotics Industries Association (RIA), and U.S. Occupational Safety
& Health Administration (OSHA), among others. Requirements are numerous;
some are more obvious than others. From automationworld.com and Siemens.
Impact
of the New International Safety Standards from NHP
1.10
Safety
of machinery - Notes on the application of standards EN 62061 and EN ISO 13849-1-
Are you a machine manufacturer or system integrator? Do you upgrade machinery?
This is what you need to consider in future in terms of functional safety! What
do you need to do to place a machine on the market in compliance with the
directives? The EU Machinery Directive stipulates that machinery should not
present a risk (risk assessment in accordance with EN 1050 or EN ISO 14121-1).
Given that there is no such thing as zero risk in technology, the aim is to
achieve an acceptable residual risk. This technical article compares the two
standards. From Siemens.
1.10
The following useful technical notes are from Leuze
Electronic.
UK HSE documents
The Strategy for Workplace Health and Safety in Great Britain to 2010 and beyond' http://www.hse.gov.uk/aboutus/hsc/strategy.htm
INDG163, 'Five Steps to Risk Assessment'
http://www.hse.gov.uk/pubns/raindex.htm
RR216, 'A methodology for the assignment
of safety integrity levels (SILs) to safety-related control
functions implemented by safety-related electrical, electronic and
programmable electronic control systems of machines'
http://www.hse.gov.uk/research/rrhtm/rr216.htm
INDG316, 'Procedures for daily inspection
and testing of mechanical power presses and press brakes'
http://www.hse.gov.uk/pubns/engindex.htm
INDG375, 'Power presses: a summary of
guidance on maintenance and thorough examination'
http://www.hse.gov.uk/pubns/puwerind.htm
INDG229, 'Using work equipment safely'
http://www.hse.gov.uk/pubns/puwerind.htm
INDG270, 'Supplying New Machinery: a
Short Guide'
http://www.hse.gov.uk/pubns/puwerind.htm
INDG271, 'Buying New Machinery: a Short
Guide'
http://www.hse.gov.uk/pubns/puwerind.htm
INDG291, 'Simple guide to the Provision
and use of Work Equipment Regulations 1998'
http://www.hse.gov.uk/pubns/puwerind.htm
RR125, 'Evaluation of the implementation
of the use of work equipment directive and the amending directive
to the use of work equipment directive in the UK'
http://www.hse.gov.uk/research/rrhtm/rr125.htm
HSC13, 'Health and Safety Regulation: a
Short Guide'
http://www.hse.gov.uk/pubns/regindex.htm
INDG275, 'Managing Health and Safety:
Five Steps to Success'
http://www.hse.gov.uk/pubns/manindex.htm
INDG343, 'Directors' Responsibilities for
Health and Safety'
http://www.hse.gov.uk/pubns/manindex.htm
'Directors' Responsibilities for Health and
Safety (INDG343): Frequently Asked Questions'
http://www.hse.gov.uk/pubns/manindex.htm
The PilzUK newsletter is also a very useful technical resource
Other Links
The following articles are from the excellent publication Robotics online.
PROFIsafe:
Networked Safety for Process and Factory Automation -ARC presents some
compelling benefits for using PROFIsafe and two success stories.
Programmable
safety begets new standard - Safety-integrity levels spelled
out in European standards increasingly impact equipment designers in the U.S. -
Dave Collins Schneider Electric - Thanks to Machinedesign.com
11.09
The Following are available from Proctor Machine
Guarding - A short registration process is required to access them but it is
worth it.
Risk
Assessment Calculator (XLS) - A free Risk Assessment
Calculator that is based on the requirements of BS EN 1050, the standard for
machinery risk assessments. Designed to be easy to use, the Risk Assessment
Calculator incorporates checklists and look-up tables to enable risk assessments
to be carried out on almost any static machinery. A Hazard Rating Number (HRN)
and Risk Level are calculated automatically for each identified hazard, thereby
indicating at-a-glance where users should consider taking action. The Risk
Assessment Calculator is based on a Microsoft Excel spreadsheet, though very
little knowledge of this software package is required in order to use the tool.
All of the calculations are handled automatically, leaving the user to enter the
data and decide on the values to use for 'Likelihood of Occurrence', 'Frequency
of Exposure', 'Degree of Possible Harm' and the 'Number of Persons at Risk'
using the guides provided.
Free
Guide to Machinery Guarding Standards - A free guide to machinery guarding
standards. Available as a PDF document that can be printed by the recipient,
this guide is the second edition of the hugely popular 'On Your Guard', updated
to reflect changes in standards and with additional references to conveyor
guarding.
Workshop
Safety Free Guide - A free guide to workshop safety that will benefit anyone
responsible for the safety of machinery and work equipment. The guide
covers the folllowing topics: costs and benefits; regulations and legislation;
general requirements for machine guards; specific machine types; other measures
relating to machinery safety; standard; official information and guidance;
useful resources; and sources of further information.
Machine
Accident Investigation Kit - a free Machine Accident Investigation Kit that
will help small and medium-sized manufacturing companies perform investigations
so that they meet their statutory obligations and prevent similar accidents from
occurring in the future.
Safety
Distance Calculator (XLS) - a free Safety Distance Calculator for
establishing the required safety distances and heights of machine guards in
accordance with BS EN 294, Safety of machinery - Safety distances to prevent
danger zones being reached by the upper limbs.
Guide
to the new Machinery Directive -On 29 December 2009 the existing Machinery
Directive will be replaced by a new Directive 2006/42/EC, which has important
implications for companies building or importing machinery for use in the
European Economic Area. Procter Machine Guarding is offering a free 'Guide to
the New Machinery Directive' to help companies prepare for the new regime.
Although the main thrust of the new Directive is simplification and
clarification - especially with regard to relationships with other Directives -
there are other changes that will have a significant impact. In this third
amendment of the Machinery Directive, alterations have been made in respect of
the scope, partly-completed machinery, fixed guards, conformity assessment
procedures, enforcement and other areas.
FREE
White Paper: new Machinery Directive and Fixings for Fixed Guards - The new
Machinery Directive 2006/42/EC and the latest edition of the guarding standard
BS EN 953 include a requirement for fixings for fixed guards to remain attached
when the guards are removed. This white paper explains the requirement and
provides information to help designers select fasteners for particular guarding
applications. Useful design tips will also help to minimise the costs
associated with installing captive fasteners.
1.10
Other Useful Information - Thanks to
Leuze Electronic.
Machine Safety in the EU
Introduction
1.1 European Directives
1.2 Machinery Directive
98/37/EG
1.3 The new Machinery
Directive 2006/42/EG
1.4 Use of Work
Equipment Directive 89/655 EEC
1.5 Correlation between
directives and harmonized European standards
1.6 Formulation process
of a harmonized standard
1.7 Hierarchy of
European standards for machine
1.8 Examples of EN and
ISO/IEC standards in the machine safety area
1.9 Safety of
machinery, risk analysis and risk assessment
1.10 Safety-related
parts of control systems
1.11 EN 954-1:
„Safety of machinery – Safety-related parts of control systems"
1.12 EN ISO 13849-1
"Safety of machinery – Safety related parts of control systems – Part
1: General principles for design"
1.13 IEC/EN 62061
"Safety of machinery – Functional safety of safety-related electrical,
electronic and programmable electronic control systems"
Machine Safety in the USA
Introduction
2.1 OSHA Regulations
2.2 US Standards, ANSI,
NFPA, UL
2.3 Strategy for Risk
Reduction
2.4 Control Reliability
Switches
Switches-
Some excellent technical links from the Switches Reference Centre