Festo - Machine Safety 101

Machine Safety 101
Guidelines for meeting Machine Safety Directive EN ISO 13849-1
Frank Langro Festo Corporation Director Marketing & Product Management

IM-CRC/Alexander Weinhard Hallo Welt! 5. April 2011 gendert: 7. April 2011, LPK Entwurf Vertraulich
Machine Safety 101

Machine Safety
Why?
Standards Determining Safety Level Summary
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Machine Safety 101: Why?
Contrary to popular opinion, all of us are not as smart, or safe, as we think we are..
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Machine Safety 101: Why?
Protect people
Protect companies
Protect product
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Machine Safety 101: Standards

What is Safety?
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What is Safety?
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Laws e.g. EC Machinery Directive
Risk assessment Risk analysis Risk assessment Risk reduction Design measures Technical measures User Information
Risk reduction Safe machines
Solutions from Festo
Safety function
Input
Logic
Output
Evaluation :
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PL PLr
SIL SILr
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evaluation whether risk reduction is sufficient

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Machine Safety 101: Determining Safety Levels

Procedure from DIN EN ISO 13849-1
5 steps to determine the safety level according to 13849-1
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STEP 1 Risk Assessment according to DIN EN ISO 13849-1
low risk
high risk
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STEP 2 Specification of categories based on Designated Architecture
1 channel, no feedback
1 channel, feedback, 100x test required
2 channel, feasible failure detection

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2 channel, high level of failure detection

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Step 2, Find Category based on Control Architecture
Determined PLr (required)
Not suitable due to test requirement
Suitable Category
Cat. 3 Control Architecture from this example

STEP 3 Mean Time to Dangerous Failure ( MTTFd )
Mean number of cycles until 10% of components fail dangerously
Cycles/yea r Done for all channels
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STEP 4 Determining Diagnostic Coverage
Used for categories required to have diagnostic testing to check if the safety function still works. This can be multiple forms, ie: sensor feedback self test Total dangerous failure rate. MTTF is part of calculation. Ratio of recognized dangerous errors vs total dangerous errors Customer to calculate the DC in a pneumatic circuit. Not found in components.

STEP 5 CCF Common Cause Failure
Checklist for common faults, ie wire coming loose PCB traces too close common parts / common failure Points detracted if conditions not met Points must be >= 65
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If all 5 steps pass, system is PL d, Cat. 3, Sil 2
Determined PLr (required)
Not suitable due to test requirement
Suitable Category Cat. 3 Control Architecture from this example
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IFA:
German Government institution for Occupational Safety & Health IFA developed SISTEMA which is the gold standard sw tool for evaluating the safety related part of machinery according to EN ISO 13849-1 Free-of-charge download Prepare documentation required for the European Machinery Directive, and necessary steps for a http://www.dguv.de/ifa/Praxishilfen/Software/SISTEMA/index-2.jsp proper
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IFA influence is not just for Germany:

IFA collaborates with ANSI Rockwell is developing a sw tool for their customers called Safety Automation Builder. It interfaces with SISTEMA, using their sw for analysis
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Machine Safety 101: Summary

Protecting: Product, companies, & PEOPLE International Standards: EN ISO 13849-1 Globally accepted Documentation: MUST HAVE !!!
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Machine Safety 101
Thank you. Questions
www.festo.com/us www.festo.us/safety
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Festo - Machine Safety 101

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Machine Safety 101

Guidelines for meeting Machine Safety Directive EN ISO 13849-1

Frank Langro Festo Corporation Director Marketing & Product Management

Machine Safety 101

gendert: 7. April 2011, LPK

Machine Safety 101: Why?

Machine Safety 101: Why?

gendert: 7. April 2011, LPK

Machine Safety 101: Standards

gendert: 7. April 2011, LPK

Machine Safety 101: Standards

gendert: 7. April 2011, LPK

Machine Safety 101: Standards

gendert: 7. April 2011, LPK

Machine Safety 101: Standards

Solutions from Festo

evaluation whether risk reduction is sufficient

Machine Safety 101: Standards

gendert: 7. April 2011, LPK

Machine Safety 101: Standards

gendert: 7. April 2011, LPK

Machine Safety 101: Determining Safety Levels

5 steps to determine the safety level according to 13849-1

gendert: 7. April 2011, LPK

Machine Safety 101: Determining Safety Levels

Annex A, EN 13849-1 5. April 2011 gendert: 7. April 2011, LPK

Machine Safety 101: Determining Safety Levels

1 channel, feedback, 100x test required

2 channel, feasible failure detection

2 channel, high level of failure detection

Machine Safety 101: Determining Safety Levels

Determined PLr (required)

Not suitable due to test requirement

Machine Safety 101: Determining Safety Levels

Cycles/yea r Done for all channels

gendert: 7. April 2011, LPK

Machine Safety 101: Determining Safety Levels

Machine Safety 101: Determining Safety Levels

gendert: 7. April 2011, LPK

Machine Safety 101: Determining Safety Levels

Determined PLr (required)

Not suitable due to test requirement

Suitable Category Cat. 3 Control Architecture from this example

gendert: 7. April 2011, LPK

Machine Safety 101: Determining Safety Levels

Machine Safety 101: Determining Safety Levels

IFA influence is not just for Germany:

gendert: 7. April 2011, LPK

Machine Safety 101: Summary

gendert: 7. April 2011, LPK

Machine Safety 101

Thank you. Questions

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