In the manufacturing industry, any area where humans and machines intersect becomes an area of potential danger. Even in the modern production line, humans often prove vital in production or packaging processes; however, conveyor belts, robotic arms, cutting blades and other moving machines can cause serious injury and even death.
The European Machinery Directive has a strong emphasis on safety. One of its key goals is the reduction of industrial accidents. In areas where human-machine cooperation is necessary, life and health are to be prioritized, and risks must be minimized. Therefore, machines and systems must be designed in such a way that there is no room for error or defects that could pose a danger to people.
Several European countries have built their reputations on the production of safe, reliable and sophisticated industrial machines and systems, which are almost always designed, installed and maintained by prioritizing functional safety elements. Nevertheless, there are still many machines designed without the interests of users being the priority. In addition to being impractical, these machines prevent operators from doing their jobs, often increasing safety risks, especially if the operator bypasses or ignores essential safety functions.
What exactly is functional safety?
It is, roughly speaking, the automatic safety feature that ensures the proper execution of the intended function or, where this is not possible, the orderly- therefore safe- shutdown of the system. Functional safety is governed by the two major industry standards on safety life cycle and different types of failures caused by errors: IEC61508 and IEC61511.
For machine designers, it is obvious that compliance with the Machinery Directive is not only achieved by purchasing components with safety certification. A comprehensive risk and hazard assessment should be conducted to ensure that not only operator safety but also ease of use is guaranteed. Once the design phase is completed, technical safety measures need to be implemented, such as placing guards around the machine and choosing components with excellent functional safety functions.
The ability to stop the process of motion control machines, including servomotors and servo drives, is becoming increasingly important, especially for critical elements such as brakes or vertical axes. It is essential to make sure that the reaction time of stopping is so fast that body parts are safeguarded from the force of the moving organs, a function that needs to be checked frequently.
Moreover, shutdown systems must prove responsive and flexible in applications where a particularly high degree of safety is required, such as in production and packaging machinery. Functional safety components can be connected through safety input-output (I/O) or other proprietary bus systems, although the most advanced solutions are those based on the powerful and flexible safety fieldbuses.
Functional Safety over EtherCAT
Parker now offers an advanced range of PSD products with Functional Safety over EtherCAT (FSoE) protocol capable of providing a complete, centralized functional safety solution that requires no additional wiring.
A powerful and freely programmable FSoE master, Parker’s safety PLC addresses all safety components through the network, including safety inputs and outputs, as well as PSD drive controllers, with integrated safety technology. External components such as light curtains, emergency pushbuttons and stop mats are connected through the safety I/O modules.
If functional safety is implemented properly, the operator will find no obstacle or reason to avoid safety devices. Similarly, safety features do not adversely affect machine productivity; on the contrary, they ensure uniformity and efficiency on the processing line.
But what is more important is that the benefits of using servo drives with built-in safety features cannot be ignored, including reduced wiring and components, ease of use, and increased productivity. Functional safety also has much to offer Industry 4.0. Not only is safety set to become increasingly important in automated factories, where the degree of trust between man and machine will need to be increased, but safety systems will also improve diagnostics, efficiency and reliability.
Watch the movie to learn about all the safety functions of the PSD drive.
This article was written by Patrick Knebel, product manager – servo drives and controllers, Electromechanical and Drives Division Europe, Parker Hannifin Corporation
Related articles:
What is meant by “cutting edge” in the case of control systems for functional safety?
In pneumatics school: the Machinery Directive
Return on IoT investment for OEMs
In the manufacturing industry, any area where humans and machines intersect becomes an area of potential danger. Even in the modern production line, humans often prove crucial in production or packaging processes; however, conveyor belts, robotic arms, cutting blades and other moving machines can cause serious injury and even death.
The European Machinery Directive has a strong emphasis on safety. One of its key goals is the reduction of industrial accidents. In areas where human-machine cooperation is needed, life and health are to be prioritized, and risks must be minimized. Therefore, machines and systems must be designed in such a way that there is no room for error or defects that could pose a danger to people.
Several European countries have built their reputations on the production of safe, reliable and sophisticated industrial machines and systems, which are almost always designed, installed and maintained by prioritizing functional safety elements. Nevertheless, there are still many machines designed without the interests of users being the priority. In addition to being impractical, these machines prevent operators from doing their jobs, often increasing safety risks, especially if the operator bypasses or ignores essential safety functions.
What exactly is functional safety?
It is, roughly speaking, the automatic safety feature that ensures the proper execution of the intended function or, where this is not possible, the orderly- therefore safe- shutdown of the system. Functional safety is governed by the two major industry standards on safety life cycle and different types of failures caused by errors: IEC61508 and IEC61511.
For machine designers, it is obvious that compliance with the Machinery Directive is not only achieved by purchasing components with safety certification. A comprehensive risk and hazard assessment should be conducted to ensure that not only operator safety but also ease of use is guaranteed. Once the design phase is completed, technical safety measures need to be implemented, such as placing guards around the machine and choosing components with excellent functional safety functions.
The ability to stop the process of motion control machines, including servomotors and servo drives, is becoming increasingly important, especially for critical elements such as brakes or vertical axes. It is essential to make sure that the reaction time of stopping is so fast that body parts are safeguarded from the force of the moving organs, a function that needs to be checked frequently.
Moreover, shutdown systems must prove responsive and flexible in applications where a particularly high degree of safety is required, such as in production and packaging machinery. Functional safety components can be connected through safety input-output (I/O) or other proprietary bus systems, although the most advanced solutions are those based on the powerful and flexible safety fieldbuses.
Functional Safety over EtherCAT
Parker now offers an advanced range of PSD products with Functional Safety over EtherCAT (FSoE) protocol capable of providing a complete, centralized functional safety solution that requires no additional wiring.
A powerful and freely programmable FSoE master, Parker’s safety PLC addresses all safety components through the network, including safety inputs and outputs, as well as PSD drive controllers, with integrated safety technology. External components such as light curtains, emergency pushbuttons and stop mats are connected through the safety I/O modules.
If functional safety is implemented properly, the operator will find no obstacle or reason to avoid safety devices. Similarly, safety features do not adversely affect machine productivity; on the contrary, they ensure uniformity and efficiency on the processing line.
But what is more important is that the benefits of using servo drives with built-in safety features cannot be ignored, including reduced wiring and components, ease of use, and increased productivity. Functional safety also has much to offer Industry 4.0. Not only is safety set to become increasingly important in automated factories, where the degree of trust between man and machine will need to be increased, but safety systems will also improve diagnostics, efficiency and reliability.
Watch the movie to learn about all the safety functions of the PSD drive.
This article was written by Patrick Knebel, product manager – servo drives and controllers, Electromechanical and Drives Division Europe, Parker Hannifin Corporation
Related articles:
What is meant by “cutting edge” in the case of control systems for functional safety?
In pneumatics school: the Machinery Directive
Return on IoT investment for OEMs
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