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 Controls
Today we live in a “Global Environment”. Competition is everywhere. This competition is driving technology advancement across the globe. ROSS Controls
Tech chnolo logy gy is s cha hang nging ing in ever ery te tech chnolo logy gy se segm gment. t. Today Self-driving 2010’s Electric Early 2000’s Hybrid 1900-2000 Gasoline only Early 1900’s - 1990’s 1990’s Bag Early 2000’s Flip Today Mid 2000’s Wired Apple Watch Smart ROSS Controls
Safety ty Techn chnolo ology gy is s evolv olvin ing g in a si simil milar ma mann nner er Mach chines s are e evol olving with new new tech chnolog ogies es tha hat re require e adv dvanced ed func unction onality. Safety Technology Advancements • Fixed Guarding • Moveable Guarding • Safety Interlocks • Presence Sensing Devices • Collaborative Systems ROSS Controls
Let’s take a look at how these advancements are affecting electrical safety solutions! Machine safety is evolving with new technologies that improve safety and productivity. Late 1980’s & 1990’s 1970’s & early 80’s • Semi-integrated Safety • Integrated Safety • Standard Products • Discrete Safety • Safety Controllers • Advanced safety & • Standard PLC’s • Standard PLC’s • Safety PLC’s security control systems • Basic Relays • Basic Safety Relays • Safety Servo’s & VFD’s • Collaborative robots 2000’s Today oday • Panel lights • HMI’s • Safety Valves • Personnel ID systems • Pushbuttons • Electronic Safety Switches • Electronic Presense • Adaptive machine • Basic Safety Switches Detection • Light curtains functions • Basic Safety Circuits • Advanced safety circuits • 2 channel safety circuits • Self configuring systems ROSS Controls
Safety & Con ontrol l Solu lutions s of f the he pas past Physically Independent ROSS Controls
Safety and nd Con ontrol Solu olutio ions of today Physically Combined ROSS Controls
The main reason that safety systems s are advancing is because se tech chnology is advancing. 70% 30% Controllers & PLC’s Controllers & PLC’s 30% 70% Relays Relays 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. ROSS Controls
Fluid id Pow ower Safety Solu olutio ions are evolv lvin ing too! oo! Fluid power solutions are evolving the same way electrical products did 10 to 15 years ago. Late 1980’s & 1990’s 1970’s & early 80’s • Turning off power • Use of safety relays, • Use of basic safety • Use of advanced safety with standard safety controllers & relays to turn off control systems controls was good safety PLC’s standard solenoids. • Use of multi-function enough. • Use of redundant 2000’s • Use of blocked & open fluid power safety oday Use of standard • safety solenoids Today center solenoids solutions solenoids (SR) • Use of dedicated LOTO • Use of lockable ball • Use of modular LOTO Use of standard • valves valves systems ball valves ROSS Controls
Our older products were self monitored but were large and expensive. Our new products are smaller and match the electrical safety transition. Contemporary Products Old Products with Internal Current Products with with External Monitoring Monitoring Electrical Internal Monitoring Pneumatic safety solutions are evolving with solutions that make them easier to integrate. ROSS Controls
The he reaso reason tha hat tha hat flui uid po power r safety y was s no not add ddresse sed un until later er than electrical safety is because the standards didn’t include it. 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. European Machine Directive 2006/42/EC OSHA Machine Safety 1910.xxx Machine Safety - General Safety Requirements Machine Safety - Basic concepts General Safety Requirements ANSI B11.0 EN/ISO 12100 Machine Safety - Principles for Risk Assessment Machine Safety - Principles for Risk Assessment ANSI/RIA TR15.306 Risk Assessment Requirements EN/ISO 14121 Machine Safety - safety- Machine Safety - Machine Safety - Selection of Programmable related parts of control Functional safety of Electronic Systems (PES/PLC) for Machine Tools Design Requirements systems EEPES control systems ANSI B11.19 EN/ISO 13849-1 IEC 62061 Fluid Power Requirements Pneumatic Safety – EN/ISO 4414 Pneumatic Safety – ANSI B11.0 Hydraulic Safety – EN/ISO 4413 Hydraulic Safety – ANSI B11.0 Electrical equipment of machines Machine Safety - Electrical equipment of machines Electrical Requirements ANSI/NFPA 79 IEC 60204-1 Notice that there are specific standard for Fluid Power Safety. ROSS Controls The Global Leader in Fluid Power Safety Solutions
ISO12100 & ANSIB11.0 outline the basic requirements for risk assessment & risk reduction. The ISO12100 and ANSIB11.0 methodologies provide a systematic approach as shown in the flow chart below. Risk Assessment Assessment Determine the Limits Identify the Hazards Estimate the Risk Evaluate the Risk The top part of ISO12100 and ANSI B11.0 deal with assessing risk. ROSS Controls The Global Leader in Fluid Power Safety Solutions
ISO4414 & ISO4413 say that hydraulics & pneumatics must be considered and identified risk must be eliminated or reduced. There are specific requirements for the use, implementation and utilization of hydraulic and pneumatic components in control systems according to ISO13849-1. ROSS Controls The Global Leader in Fluid Power Safety Solutions
This means that we need to think about… We need to think about powered and unpowered hazards, like falling loads! The Global Leader in Fluid Power Safety Solutions Ross Controls
There are a number of risk estimation methods that yield varying results. ISO13849 has become one of the most widely used methodologies. TR13.306 Methodology ROSS Controls The Global Leader in Fluid Power Safety Solutions
The reason that many companies have adopted ISO13849 is because it addresses all technologies and provides a more holistic approach to machine safety. EN 954-1 EN ISO 13849-1 Electrical Control Circuits Control circuits all technologies : EN954-1 was withdrawn in • Electrical Not just electrical 2011. The only place that • Pneumatic anymore! Categories exist today is • Fluids as a part of ISO13849. • Hydraulic Safety Categories B, 1, 2, 3 & 4 Performance Levels PLa to PLe Safety provided by the structure Safety provided by: • of the control circuit The architecture/structure (EN954-1 categories) • The reliability of the system (MTTF d , B10 d ) • The diagnostic coverage of the system (DC) • The preventive measures against common ISO13849 adds some important causes of failure (CCF) factors that must be considered in the selection design and implementation of safety solutions Draw a diagram (schematic) Draw a diagram and verification of PL The Global Leader in Fluid Power Safety Solutions Does PL(achieved) = PLr (required) ? ROSS Controls
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. ROSS Controls
ANSI B11.0 & EN13736 provide performance requirements based on pressure & force. If fluid power hazards are moderate, serious or catastrophic the safety solution has to meet PLc, PLd or PLe. Ross Controls The Global Leader in Fluid Power Safety Solutions
Once we are done with the assessment we need to determine how to reduce risk. This should include fluid power risk as well. Risk Reduction Reduction by Elimination Reduction by Design Reduction by Guarding Reduction by Safeguards Reduction by Information & PPE The bottom part of ISO12100 and ANSI B11.0 deal with risk reduction. ROSS Controls The Global Leader in Fluid Power Safety Solutions
Let’s look at the list of Safety Functions from ISO13849 -1. 1. Safeguard Elimination Safeguard Parameterized Safeguards Safeguard The ones circle Th led in re red apply ly to to fluid id power r safety as well. l. Th The follo lowin ing slides will l show how these are re used in modern rn Safeguard safety ty solutio ions. ROSS Controls
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