Safety-Key to the Machine Solutiontools.se-ace.com/transfers/inx_files/presentations/Safety... · · 2012-10-17Schneider Electric - Industry Business – Safety-Key to the Machine

2011 Schneider Electric. All Rights Reserved.

Safety-Key to the Machine Solution

Dave Collins Schneider Electric Industry NOW Express

2 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

Confused about safety?

● You are not alone

● Almost 60% are not aware of Safety Categories

● 68% not familiar with Performance Levels

● Most have difficulty in applying safety products


Standards

● Safety is driven by standards

● Standards determine devices to use, how to use them, and sometimes how safety products are constructed

● Some US standards are similar to IEC standards


US Standards

A few of the most important US Standards are: ● OSHA 29 CFR1910

● NFPA 79, 2007 Edition, Electrical Standard for Industrial Machinery

● ANSI B11.19, Performance Criteria for Safeguarding

● ANSI/RIA R15.06, Industrial Robots and Robot Systems, Safety Requirements

Locally ● UL and CSA (in Canada)

● UL is mandatory in most US cities in their codes and requirements. ● Customers and users demand these approvals even if local codes do

not require it. Canada ● CSA is mandatory in Canada


European / International Standards

● Safety categories (B, 1, 2, 3, 4) per EN 954-1 are no longer valid since December 31, 2011

● Performance Levels (a, b, c, d, e) per EN/ISO 13849-1 replaced safety categories on January 1, 2012

● SIL (Safety Integrity Levels) are designed for use primarily for more complex systems or microprocessor and software based systems

● SIL can be determined by either IEC 61508 or IEC 62061


Starting point for the

evaluation of the risk

a

b

c

d

e

P1

P2 P1

P2

P2

P2

P1

P1

F2

F1

F1

F2

S1

S2

Required performance

level (PLr)

Low contribution to risk reduction

High contribution to risk reduction

S Severity of injury S1 Slight (normally reversible injury) S2 Serious (normally irreversible) injury including death F Frequency and/or exposure time to the hazard F1 Seldom to less often and/or the exposure time is short F2 Frequent to continuous and/or the exposure time is long P Possibility of avoiding the hazard or limiting the harm P1 Possible under specific conditions P2 Virtually impossible

EN/ISO 13849-1 Risk graph and parameters

Uses the same criteria as EN 954-1


EN/ISO 13849-1

● EN/ISO 13849-1 adds new parameters to the requirements of the categories of EN 954-1 in order to determine the Performance Level (PL): ● MTTFd = mean time to dangerous failure

Three levels of MTTFd are defined in this standard in order to classify the requirements of the categories and the performance levels (PL):

● DC = diagnostic coverage

DC = λdd / λd total

Denotation of mean time to dangerous failure Range of MTTFd

low 3 years <= MTTFd < 10 yearsmedium 10 years <= MTTFd < 30 years

high 30 years <= MTTFd < 100 years

Denotation of diagnostic coverage Range of DCnone DC < 60%low 60% <= DC < 90%

medium 90% <= DC < 99%high 99% <= DC

ldd / ld total total failures Dangerous

detected failures Dangerous

total d

dd

==

λλ


EN/ISO 13849-1 Relationship between categories, DC, MTTFd and PL

MTTFd of each channel = low MTTFd of each channel = medium MTTFd of each channel = high

* In many applications the realization of performance level c by category 1 may not be suf f icient. In this case a higher category e.g. 2 or 3 should be chosen.

a *

b 1

c 1

d 2

e 3

Cat. BDC avg =

0

Cat. 1DC avg =

0

Cat. 2DC avg =

low

Cat. 2DC avg =medium

Cat. 3DC avg =

low

Cat. 3DC avg =medium

Cat. 4DC avg =

high

Perf

orm

ance

leve

l

Saf

ety

Inte

grity

Lev

el

*

DC = Diagnostic Coverage MTTFd = Mean Time To Failure - Dangerous PL = Performance Level


100 % of flexibility and optimization with Flexible Machine Control

1 software environment Simplify machine programming & commissioning with SoMachine suite

Multiple hardware Control Platforms Embedded Intelligence where it is needed

Logic controllers

Motion controllers

HMI controllers

Drive controllers I/Os

Safety is at the center of it all


Ready-to-use architectures: TVDA

● Predetermined equipment lists

●Tested ● our experts tested each application

to ensure that they work in all possible configurations.

●Validated ● Full functional compatibility of

devices.

●Documented ● a full user manual contains all the

required information for installation and assembly, including CAD and wiring diagrams


The ‘Safety Chain’ approach

Acquire the information Monitor and processing Stop the machine

Safe signal transmission

● One provider for the complete safety chain: ● Reduce cost on the machine safety application through a single

automation and complete safety chain provider


● Fully aligned with our TVDA approach: ● Answers the machine customer’s needs, complementary with our

automation architectures

Safety Chain Solution

Safe Stop 1 - servo TVD Architecture

Safety Chain Solution

14 Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012

●Optimized implementation for increased levels of protection ●A cost optimized solution that reaches a very low

probability of dangerous failure (PFHd), which corresponds to PL e and SIL 3

●Typical applications: ●Assembling, machining centers or similar

machines tools

Safe Stop 0, High performance

Safety Chain Solutions



●Safety integrated devices for an easier safety chain configuration ● The drive (ATV32) features an integrated safety

torque off function (STO), which meets the requirements of PL e and SIL 3

●Typical applications: ● Textile, wood-working or simple packaging

machines

Safe Stop 1, Drive - high performance


● Improved accuracy through safety integrated devices ●Stopping the machine with the Safe Stop 2

(SS2) function by using the enhanced safety module (eSM) integrated on the servo-drive; it meets the requirements of PL e and SIL 3

●Typical applications: ●Packaging, printing, conversion, or similar

machines with long freewheel stopping times (high inertia or low resistive torque)


Safe Stop 2, Servo - enhanced safety


What can we do for our customers?

Schneider Electric provides a wide variety of scalable and cost effective solutions from simple electromechanical to programmable systems with safety communications, to meet Performance Level “e”, and SIL 3 as well as local and international safety requirements, to help maximize productivity.


Monitor and processing Type Safety

Relay Safety

Controller Safety PLC AS-I

Safety Card

Family XPS XPSMC XPSMF ASISAFE

Lexium 32

Function Solution for monitoring one

function

Solution for monitoring several

functions simultaneously

Solution for monitoring many

functions simultaneously

and communication

over Safe Ethernet

Solutions using a safety related

communications bus

Solutions using a motion controller


Lexium eSM and Adapter Hardware

• Optional eSM Terminal Adaptor

• for LXM32 M

• Accessories: - eSM Terminal adapter (Connection of up to 5 Lxm) - eSM Cable

AC


Acquire the Information Type Safety Interlock Safety Interlock Safety Interlock

Family XCSA XCSB XCSC

Enclosure Metal Metal Metal

Function Non-Locking Locking by Push Button Locking by Key


Acquire the Information Type Safety Interlock Safety Interlock Safety Interlock Safety Interlock

Family XCSE XCSL XCSLE & XCSLF XCSTE

Enclosure Metal Metal Metal - XCSLF Plastic - XCSLE

Plastic

Function Solenoid Locking Solenoid Locking Solenoid Locking Solenoid Locking


Acquire the Information Type Safety Interlock Safety Interlock Safety Interlock Safety Interlock

Family XCSPA XCSPL XCSPR XCSMP

Enclosure Plastic Plastic Plastic Plastic

Function Non-Locking Non-Locking Non-Locking Non-Locking


Acquire the Information Type Non-Contact Non-Contact Non-Contact Non-Contact

Family XCSDMC XCSDMP XCSDMR XCSDM3/4

Operating Zone

Sao: 0.20 in (5 mm) Sar: 0.59 in (15 mm)

Sao: 0.31 in (8 mm) Sar: 0.79 in (20 mm)

Sao: 0.31 in (8 mm) Sar: 0.79 in (20 mm)

Sao: 0.39 in (10 mm) Sar: 0.79 in (20 mm)

Wiring Cable or connector Cable or connector Cable or connector Cable or connector

Size 2.01 x 0.63 x 0.28 in 3.56 x 0.98 x 0.51 in 30 mm dia. 1.51 in 3.94 x 1.34 x 1.26 in


Acquire the Information Type Compact Compact Compact Compact

Family XUSLB XUSLD XUSLPZ XUSLPB

MOS 14 mm and 30 mm 0.55 in and 1.18 in

14 mm and 30 mm 0.55 in and 1.18 in

300, 400,500,600 mm 11.8, 15.7, 19.7, 23.6 in.

500 and 600 mm 19.7 and 23.6 in

Sensing Distance

SN

1 to 22.9 ft, or 1 to 65.6 ft with PDM

1 to 22.9 ft, or 1 to 65.6 ft with PDM

2.6 to 65.5 ft or 2.6 to 229.7 ft

2.6 to 26.3 ft


Acquire the Information Type Cable Pull Switch Cable Pull Switch Emergency Stop

Family XY2 XY2 XB4 – XB5

Feature Adjustable tripping force Viewing windows to aid in adjusting cable tension

Conforms to ISO 13850

Cable Length 165 ft (50 m) 50 ft (15 m)


In addition to all of the previous products, we offer complete lines of other devices for use in safety related applications: ● E-Stop buttons, EMO ● Indicating banks ● Control Relays and Contactors ● Drives ● Motion

Other Products for the Safety Chain


Thank You!

Documents

Safety-Key to the Machine Solutiontools.se-ace.com/transfers/inx_files/presentations/Safety... · · 2012-10-17Schneider Electric - Industry Business – Safety-Key to the Machine