Modern Safety Systems and Advanced Fluid Power Solutions Chris Brogli Global VP of Safety Business Development TUV FS Expert ID#213/13 Phone: 1-859-595-9630 Email: chris.brogli@rosscontrols.com
Today we live in a Global Environment. Competition is everywhere. This competition is driving technology advancement across the globe.
Technology is changing in every technology segment. 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
Safety Technology is evolving in a similar manner Machines are evolving with new technologies that require advanced functionality. Safety Technology Advancements Fixed Guarding Moveable Guarding Safety Interlocks Presence Sensing Devices Collaborative Systems
1970 s & early 80 s Late 1980 s & 1990 s 2000 s Today 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. Standard Products Standard PLC s Basic Relays Panel lights Pushbuttons Basic Safety Switches Discrete Safety Standard PLC s Basic Safety Relays HMI s Electronic Safety Switches Light curtains Semi-integrated Safety Safety Controllers Safety PLC s Safety Servo s & VFD s Safety Valves Electronic Presense Detection Integrated Safety Advanced safety & security control systems Collaborative robots Personnel ID systems Adaptive machine functions Basic Safety Circuits 2 channel safety circuits Advanced safety circuits Self configuring systems
Safety & Control Solutions of the past Physically Independent
Safety and Control Solutions of today Physically Combined
The main reason that safety systems are advancing is because technology is advancing. 30% Controllers & PLC s 70% 70% 30% Relays Controllers & PLC s Relays In 2009 safety relays were 70% of the safety logic today 70% or the market is safety controllers & safety PLC s. This allows for better control & monitoring of the safety system.
1970 s & early 80 s Late 1980 s & 1990 s 2000 s Today Fluid Power Safety Solutions are evolving too! Fluid power solutions are evolving the same way electrical products did 10 to 15 years ago. Turning off power with standard controls was good enough. Use of standard solenoids (SR) Use of standard ball valves Use of basic safety relays to turn off standard solenoids. Use of blocked & open center solenoids Use of lockable ball valves Use of safety relays, safety controllers & safety PLC s Use of redundant safety solenoids Use of dedicated LOTO valves Use of advanced safety control systems Use of multi-function fluid power safety solutions Use of modular LOTO systems
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.
The reason that that fluid power safety was not addressed until later than electrical safety is because the standards didn t include it. ISO 13849-1 2015 required users to include fluid power safety as part of the safety control system. Most companies ignored fluid power safety until the ISO13849 standard changed in 2015.
Let s take a look at standards of today to understand the requirements. European Machine Directive 2006/42/EC OSHA Machine Safety 1910.xxx General Safety Requirements Machine Safety - Basic concepts EN/ISO 12100 Machine Safety - General Safety Requirements ANSI B11.0 Risk Assessment Requirements Machine Safety - Principles for Risk Assessment EN/ISO 14121 Machine Safety - Principles for Risk Assessment ANSI/RIA TR15.306 Design Requirements Machine Safety - safetyrelated parts of control systems EN/ISO 13849-1 Machine Safety - Functional safety of EEPES control systems IEC 62061 Machine Safety - Selection of Programmable Electronic Systems (PES/PLC) for Machine Tools ANSI B11.19 Fluid Power Requirements Pneumatic Safety EN/ISO 4414 Hydraulic Safety EN/ISO 4413 Pneumatic Safety ANSI B11.0 Hydraulic Safety ANSI B11.0 Electrical Requirements Machine Safety - Electrical equipment of machines IEC 60204-1 Electrical equipment of machines ANSI/NFPA 79 Notice that there are specific standard for Fluid Power Safety. 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. 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. 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 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 EN954-1 was withdrawn in 2011. The only place that Categories exist today is as a part of ISO13849. Electrical Control Circuits Control circuits all technologies : Electrical Not just electrical Pneumatic anymore! Fluids Hydraulic Safety Categories B, 1, 2, 3 & 4 Performance Levels PLa to PLe ISO13849 adds some important factors that must be considered in the selection design and implementation of safety solutions Safety provided by the structure of the control circuit Safety provided by: 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 causes of failure (CCF) Draw a diagram (schematic) Draw a diagram and verification of PL Does PL(achieved) = PLr (required)? The Global Leader in Fluid Power Safety Solutions
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.
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. The Global Leader in Fluid Power Safety Solutions Ross Controls
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. The Global Leader in Fluid Power Safety Solutions
Let s look at the list of Safety Functions from ISO13849-1. Safeguard Elimination Safeguard Safeguard Safeguard Parameterized Safeguards The ones circled in red apply to fluid power safety as well. The following slides will show how these are used in modern safety solutions.
Common fluid power safety solutions. Pneumatic Safety Devices & Solutions LOTO valves for control of hazardous energy Safety Exhaust/Safe Bleed valves for release of hazardous energy Safe Return/Safe Direction valve for safe control of actuators Safe Stop/Safe Load holding for safe stopping of actuators Some additional ones to mention: Safe speed control Safe pressure control
Elimination LOTO is used for maintenance, repairs and servicing of machinery.
Pneumatic LOTO Best Practices Valve should be well marked Distinct from other manual valves Valve should be differentiated by its appearance Full diameter exhaust (rapid release of stored energy) Should only be able to be locked only in off position Positive action which would indicate only two positions (ON and OFF) A method for the employee to verify that the energy 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.
Hydraulic LOTO Best Practices Valve should be well marked Distinct from other manual valves Valve should be differentiated by its appearance Should only be able to be locked only in off position Positive action which would indicate only two positions (ON and OFF) Positive OFF A method for the employee to verify that the 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.
Safeguard When we do a risk and identify the risk level we need to design our safety solution to meet the Required Performance Level. Safety Input Devices Door Switches Emergency stops Light curtains Pull-cords Area scanners Safety mats Safety cameras + Safety Logic + Safety Output = Devices Devices Safety Relays Safety Controllers Safety PLC s Safety Contactors Safety VFD s Safety Servos Safety Valves Complete Safety Function
Guarding Considerations Can you reach over, under or around the guard? Is the guard attached with hardware that requires a tool for removal? Is the guard a moveable guard? Is it interlocked? Can someone get to the hazard before it can come to a stop? Is the guard and interlock robust enough for the application? Is the interlock rated for the environment that it will operate in? Is the interlock safety rated? Can the interlock be bypassed?
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).
Safe Direction/Safe Return 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 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.
Let s look at the key differences between standard and safety products so that we can discuss advanced fluid power safety devices. Ball valves are not tamper resistant and can be locked in the on, off and in-between positions and they do not have local indication that energy has been dissipated. They are also not easily identifiable. X 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. X 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.
Example Winder unloading table 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 Extend Retract 4 2 5 3 1
Motionless 2 3 1 Example Valve sticking 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 Rotating 2 3 1
So let s spend a few minutes to talk about what is next in fluid power safety Connected & integrated fluid power safety solutions EtherNet Connected Devices I/O Link Connected Devices Collaborative Applications Safe speed solutions Safe pressure solutions
Small Machines Connectivity has changed and will continue to change over the next 3 to 5 years. Workcells & Small Lines Continuous Lines Machine safety connectivity is evolving with new technologies that improve reliability and facilitate continuous improvement thru enhanced diagnostics and improved flexibility. Hardwired Systems Cumbersome Difficult to Apply Time consuming wiring Difficult to Trouble-shoot Easily Bypassed Hard to modify (Rewire) Connected Systems Easier to Apply Faster wiring Easy trouble-shooting Diagnostics at the relay and at I/O device (LED s) Easier to modify (QD s) Networked Systems Flexible Easy to Apply Easy to trouble-shoot Enhanced diagnostics Easiest to modify (Program change)
Today this is accomplished by hardwired & quick disconnect systems. In the future we will see valves that are connected via safety networks with no hard-wired connections. 36
To support the evolving market automation & fluid power suppliers are moving from hardwired to smart & connected solutions! The result is smart and connected solutions that reduce wiring time and enhance diagnostics and improve reliability. 37
I/O Link and EtherNet based Safety are 2 protocols that are being tested. Both solutions would use quick disconnects, LED s and smart monitoring to provide system status and system health feedback. 38
Primary Justifications for Integrated Safety Solutions Wiring & installation cost reductions Simplified connectivity which reduces errors Single connectivity methodology across the line Enhanced line diagnostics for faster troubleshooting Improved validation capabilities 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 fluidpower safety, motion and servo safety utilizing a varieity of safety input devices.
Let s break this down to the cell/station level and look at wiring costs. Impact Analysis 16 stations Hardwired $20,800 Connected $3,260 Integrated $560 Hard Wiring Times 2 Door switches 8 to 12 Wires 2 Safety Valves 6 to 8 wires 2 to 5 drives 30 to 50 wires Industry average 15 minutes per wire @ $35 per hour = $1300 per station Modular Wiring Times QD block wiring 1 to 2 hours per I/O block QD connection from block to device 25 point @ 5 minutes 6 hours @ $35 per hour = $210 per station Smart & Connected Wiring Times EtherNet & Power QD connections @ 5 minutes 10 connections 1 hour @ $35 per hour = $35 per station 40
Collaborative Applications are now being used. Common Solutions Include: Safe Limited Speed Safe Limited Torque Safe Pressure Safe Position Safe Direction
Let s look at how companies are doing safe-speed and safe-pressure in Collaborative Applications today. Collaborative Machine Solutions Safe Speed Safe Torque Safe Pressure Safe Position Safe Direction Weld Station Rivet Station
Best in class companies are using these advanced technologies to improve safety and productivity. The Aberdeen study showed that the safest companies are also the most productive! 43
The automation industry is changing with technologies that improve safety and productivity. Things to consider: Are you taking advantage of these technologies? Is there more that you can do? Does your current infrastructure enable the use of new technologies? What does 1% of productivity mean to you and your company? Best in class companies see 4 to 5% better performance than others in their industry! 44
Closing Comments Fluid Power Safety is Important The Standards require us to address Fluid Power Safety Fluid Power needs to be part of the risk assessment Based on ANSI B11.0 2015 requirements and ISO4413 and ISO4414 Fluid Power components are part of the SRP/CS Safety Related Parts of the Control System according to ISO13849-1 We can t ignore Fluid Power anymore!