ABB JOKAB SAFETY Machine Safety Presentation for IAOM. ABB Inc. August 26, 2014 Slide 1

Transcription

1 ABB JOKAB SAFETY Machine Safety Presentation for IAOM August 26, 2014 Slide 1

2 Agenda You will learn about Reasons for machine safety OSHA Machine safety standards OSHA Circuit performance selection criteria Applications Products ABB Group August 26, 2014 Slide 2

3 Application Machine Safety? A wide variety of basic mechanical motions and actions may present hazards to the worker. Recognizing them is the first step toward protection from the danger they present. The basic types of hazardous mechanical motions and actions are identified below. Cutting Actions Rotating (Including In-Running Nip Points) Motions Shearing Actions Reciprocating Motions Bending Actions Transverse Motions Punching Actions ABB Group August 26, 2014 Slide 3

4 Application Machine Safety Methods As a general rule, power transmission apparatus and moving parts that present hazards are best protected by fixed guards that eliminate or reduce the hazard. For hazards at the point of operation, where moving parts actually perform work on stock, several kinds of safeguarding are possible. The most effective and practical means available must always be chosen. Safeguards can be grouped under five general classifications. ABB Group August 26, 2014 Slide 4

5 Application Guards Guards are one of the five classifications of safeguarding devices. They are defined as barriers which prevent access to danger areas. The four general types of guards are identified below. Fixed Interlocked Adjustable Self-adjusting ABB Group August 26, 2014 Slide 5

6 Application Devices A safety device may perform one of several functions. It may: Stop the machine if a hand or any part of the body is inadvertently placed in the danger area (1 and 2) Require the operator to use both hands on machine controls, thus keeping both hands and body out of danger (3) Provide a barrier which is synchronized with the operating cycle of the machine in order to prevent entry to the danger area during the hazardous part of the cycle. ABB Group August 26, 2014 Slide 6

7 Application Machine Safety Design ABB Group August 26, 2014 Slide 7

8 OSHA Risk Assessment Factors August 26, 2014 Slide 8

9 OSHA Sample Risk Assessment

10 Engineering, Consulting, and Training Services Why are Risk Assessments performed? Risk Assessment Responsible business practice and establishes a company safety culture. Perform your responsibility for due diligence. Industry consensus standards require risk assessments. It s the law OSHA All the reasons listed above can affect your bottom line. ABB Group August 26, 2014

11 Engineering, Consulting, and Training Services Who can perform a Risk Assessment? Risk Assessment Usually a Risk Assessment is done by a team EHS, Operations, Maintenance, Engineering Risk Assessments can be done by In House Personnel Machine OEM Assistance from a Qualified Outside Provider (ABB) ABB JOKAB SAFETY provides training to assist your company in recording and maintaining risk assessments ABB Group August 26, 2014

12 OSHA Sample Risk Assessment

13 OSHA Sample Risk Assessment

14 When do we fit in? Control Reliability Control reliable safety circuitry shall be designed, constructed and applied such that any single component failure shall not prevent the stopping action. The monitoring shall generate a stop signal if a fault is detected. Following detection of a fault, a safe state shall be maintained until the fault is cleared. Common mode failures shall be taken into account when the probability of such a failure occurring is significant. The single fault should be detected at time of failure. If not practicable, the failure shall be detected at the next demand upon the safety function. August 26, 2014 Slide 14

15 When do we fit in? Sample Risk Assessment August 26, 2014 Slide 15

16 When do we fit in? Sample Risk Assessment

17 When do we fit in? Sample Risk Assessment

18 Engineering, Consulting, Training Services Machine SafeGuarding Process Usually starts with a Machine Safety Evaluation These Machine Safety Standards Indicate a Risk Assessment needs to be performed on a machine ANSI B11 Standards RIA EN/ISO This establishes where your company s resources need to be used. Which may include the following steps ABB has the capability to do all or part of the SafeGuarding process depending on the company s level of expertise. ABB Group August 26, 2014

19 Safety Relays and Interlock Switches Safety Category 1 SAFETY CATEGORY ELECTRICAL = 4 MECHANICAL = 1 Switch 1 One switch on a door wired to one safety relay. Switch wired Dual Channel. August 26, 2014 Slide 19

20 Safety Relays and Interlock Switches Safety Category 1 SAFETY CATEGORY ELECTRICAL = 4 MECHANICAL = 1 Switch 1 One switch on a door wired to one safety relay. Switch wired Dual Channel. August 26, 2014 Slide 20

21 Safety Relays and Interlock Switches Safety Category 1 SAFETY CATEGORY ELECTRICAL = 4 MECHANICAL = 1 Switch 1 One switch on a door wired to one safety relay. Switch wired Dual Channel. August 26, 2014 Slide 21

22 Safety Keyed Interlock Switches Safety Category 1 Fig 1 Fig 2 Fig 3 Machine Stops Machine Runs Machine Runs Mechanical keyed interlock switches are Safety Category 1 devices! Fencing sags or becomes mis-aligned causing unwanted wear on components. Heads can be removed or rotated, fall off or break and the switch will keep the system operational in an unsafe condition. August 26, 2014 Slide 22

23 Mkey Safety Switches Safety Switches Available in Metal or Plastic housings. Industry standard foot prints. Over 1200 available versions. Keyed Interlock, Non- Contact Coded or Magnetic versions. Solenoid Locking versions for machines with inertia. Stainless Steel versions for the food industry. Ex Proof versions for harsh environments. August 26, 2014 Slide 23

24 ABB JOKAB SAFETY Switch Line Full Comprehensive Offering Range of Stainless Steel 316 machine guard switches to cope with rigorous cleaning, extreme environment and temperature demands. The housings are tested for explosive environments, IP69K and are rated to 105C (tested to 125C). Switches are available as keyed interlock, solenoid locking, non-contact magnetic and non-contact coded versions. August 26, 2014 Slide 24

25 Safety Relays and Interlock Switches Safety Category 4 Switch 1 SAFETY CATEGORY ELECTRICAL = 4 MECHANICAL = 4 Switch 2 Two switches on each door wired to one safety relay. Each switch wired to a single input for a Dual Channel system. August 26, 2014 Slide 25

26 Safety Relays and Interlock Switches Safety Category 4 SAFETY CATEGORY ELECTRICAL = 4 MECHANICAL = 4 Switch 1 One magnetic safety switch on a door wired to one safety relay. Switch wired Dual Channel. Magnetic Switches are safer products but are more subject to contact bounce. August 26, 2014 Slide 26

27 Safety Relays and Interlock Switches Safety Category 3 SAFETY CATEGORY ELECTRICAL = 3 MECHANICAL = 4 Switch 3 Switch 2 Switch 1 One switch per door for three doors wired in series to one safety relay. Switches wired Dual Channel. August 26, 2014 Slide 27

28 Safety Relays and Interlock Switches Safety Category 3 SAFETY CATEGORY ELECTRICAL = 3 MECHANICAL = 4 Switch 3 Switch 2 Switch 1 One switch per door for three doors wired in series to one safety relay. Switches wired Dual Channel. August 26, 2014 Slide 28

29 Safety Relays and Interlock Switches Safety Category 3 SAFETY CATEGORY ELECTRICAL = 3 MECHANICAL = 4 Switch 3 Switch 2 Switch 1 One switch per door for three doors wired in series to one safety relay. Switches wired Dual Channel. August 26, 2014 Slide 29

30 Safety Relays and Interlock Switches Safety Category 3 SAFETY CATEGORY ELECTRICAL = 3 MECHANICAL = 4 Switch 3 Switch 2 Switch 1 The cable is damaged between Switch 2 and Switch 3 resulting in a short between two wires in the cable. Channel 2 is shorted before Switch 3. MACHINE IS RUNNING SHORT IS NOT DETECTED. August 26, 2014 Slide 30

31 Safety Relays and Interlock Switches Safety Category 3 SAFETY CATEGORY ELECTRICAL = 3 MECHANICAL = 4 Switch 3 Switch 2 Switch 1 Switch 1 is opened which will open both channels and stop the machine. August 26, 2014 Slide 31

32 Safety Relays and Interlock Switches Safety Category 3 SAFETY CATEGORY ELECTRICAL = 3 MECHANICAL = 4 Switch 3 Switch 2 Switch 1 Switch 1 is closed which will close both channels and allow the machine to start. Channel 2 is shorted before Switch 3. MACHINE IS RUNNING SHORT IS NOT DETECTED. August 26, 2014 Slide 32

33 Safety Relays and Interlock Switches Safety Category 3 SAFETY CATEGORY ELECTRICAL = 3 MECHANICAL = 4 Switch 3 Switch 2 Switch 1 Switch 2 is opened which will open both channels and stop the machine. August 26, 2014 Slide 33

34 Safety Relays and Interlock Switches Safety Category 3 SAFETY CATEGORY ELECTRICAL = 3 MECHANICAL = 4 Switch 3 Switch 2 Switch 1 Switch 2 is closed which will close both channels and allow the machine to start. Channel 2 is shorted before Switch 3. MACHINE IS RUNNING SHORT IS NOT DETECTED. August 26, 2014 Slide 34

35 Safety Relays and Interlock Switches Safety Category 3 SAFETY CATEGORY ELECTRICAL = 3 MECHANICAL = 4 Switch 3 Switch 2 Switch 1 Switch 3 is opened which will open only channel 1 and stop the machine. August 26, 2014 Slide 35

36 Safety Relays and Interlock Switches Safety Category 3 SAFETY CATEGORY ELECTRICAL = 3 MECHANICAL = 4 Switch 3 Switch 2 Switch 1 Switch 3 is closed which will close channel 1. Safety relay goes into a Single Channel Fault and will not allow the machine to run. Locked up. August 26, 2014 Slide 36

37 Safety Relays and Interlock Switches Safety Category 3 SAFETY CATEGORY ELECTRICAL = 3 MECHANICAL = 4 Switch 3 Switch 2 Switch 1 Cycle power- Masks fault- Machine is running. Replace relay- Masks fault- Machine is running. Cycle other switches Masks fault- Machine is running. August 26, 2014 Slide 37

38 Categories of Safety Practical Applications Safety Category 4 Sensor 1 Sensor 2 Sensor 3 SAFETY CATEGORY ELECTRICAL = 4 MECHANICAL = 4 By combining non-contact dynamic Eden sensors to the Vital Controller we have now obtained a true Control Reliable, Category 4 Safety Door circuit. Less wiring, easier mounting, more diagnostics, higher safety, eliminates down time, more reliable. August 26, 2014 Slide 38

39 Eden Safety Sensor Safety Category 4 Non mechanical, non-contact, non-magnetic, Control Reliable Category 4 Safety Sensor. Up to 30 Eden Sensors can be connected to a single Vital controller. 15mm +/- 2mm alignment forgiveness. LED indication and transistor output status from each switch. August 26, 2014 Slide 39

40 Categories of Safety Practical Applications Safety Category 4 Sensor 1 Single Beam 1 E-Stop 1 SAFETY CATEGORY ELECTRICAL = 4 MECHANICAL = 4 Eden Sensors, Spot Safety Single Beams, Smile Tina E-Stops all have the Vital technology built in. All use the same 5 pin wiring, same diagnostics and same plug and play integration. August 26, 2014 Slide 40

41 Categories of Safety Practical Applications Safety Category 4 August 26, 2014 Slide 41

42 Categories of Safety Practical Applications E-Stop Light Curtain Safety Mat SAFETY CATEGORY ELECTRICAL = 3/4 MECHANICAL = 3/4 August 26, 2014 Slide 42 All other components, conventional E-Stops, Light Curtains, Safety Mats, Switches, etc. can be integrated into the Vital Solution through the use of Tina Devices. Tina looks to the device its attached to and if the condition is True it will take the signal coming in, flip it, shift it, and send it along.

43 Conventional Palm Buttons Practical Application Concerns MACHINE STOPPED Both buttons are open and the machine is in the Stop Condition. August 26, 2014 Slide 43

44 Conventional Palm Buttons Practical Application Concerns MACHINE STOPPED The first button is pressed closed and within 500ms the second button is pressed closed. August 26, 2014 Slide 44

45 Conventional Palm Buttons Practical Application Concerns MACHINE STARTS The first button is pressed closed and within 500ms the second button is pressed closed. The machine starts. August 26, 2014 Slide 45

46 Conventional Palm Buttons Practical Application Concerns MACHINE STOPPED If either button is released then the monitoring safety circuit will send the stop condition. The machine stops. August 26, 2014 Slide 46

47 Conventional Palm Buttons Practical Application Concerns MACHINE STOPPED To initiate another cycle, both buttons must open and then close again within 500ms. August 26, 2014 Slide 47

48 Conventional Palm Buttons Practical Application Concerns MACHINE STARTS To initiate another cycle, both buttons must open and then close again within 500ms. August 26, 2014 Slide 48

49 Conventional Palm Buttons Practical Application Concerns BUTTON STICKS! August 26, 2014 Slide 49 MACHINE STARTS The number one failure of push buttons is sticking. If you remove your hand and the button sticks, THE MACHINE WILL NOT STOP! This is what happens when non-safety rated products are used in safety applications.

50 Conventional Palm Buttons Practical Application Concerns BUTTON STICKS! MACHINE STARTS If the operator reaches into the machine as an After Grasp to adjust a part he will expose his hand to the hazard point. August 26, 2014 Slide 50

51 Conventional Optical Buttons Practical Application Concerns MACHINE STOPPED This failure mode also occurs with optical style buttons. Optical initiation buttons are not approved as safety devices! August 26, 2014 Slide 51

52 Conventional Optical Buttons Practical Application Concerns MACHINE STOPPED Both buttons must still be made within 500ms for a Safe Start. August 26, 2014 Slide 52

53 Conventional Optical Buttons Practical Application Concerns MACHINE STARTS Both buttons must still be made within 500ms for a Safe Start. August 26, 2014 Slide 53

54 Conventional Optical Buttons Practical Application Concerns MACHINE STARTS Any contamination on the optical button will read as a false on. Common causes are oil, grease, dirt, sleeves, gloves, tools. A Safe Start, NOT A SAFE STOP! August 26, 2014 Slide 54

55 SafeBall 2 Hand Control Safety Category 4 Completely new HANDS ON approach has been developed. SafeBall is a spherical ball with TWO INDEPENDENT PUSH BUTTON ACTURATORS. The risk of unintentional activation is minimized. Simple and ergonomic to use device. August 26, 2014 Slide 55

56 JSHD4 3 Position Enabling Device Safety Category 4 Category 4 solution to manual bypassing of safety devices during non-hazardous portions of the machine cycle. 3 Position detects if the Enabling Device is fully squeezed or released. Optional cheat detect sensor is integrated into the handle to determine the difference between a hand and a zip tie. Optional status LED s and aux. buttons for further functionality. August 26, 2014 Slide 56

57 E Strong Emergency Stop Buttons E Strong Emergency Stop Buttons are designed for the most demanding of environments. Available with integrated LED or lockable shroud. Stainless Steel enclosure ideal for the food industry. Ex Proof rated versions for harsh environments. August 26, 2014 Slide 57

58 Focus II Safety Light Curtains Now Made in the USA Focus II consists of a transmitter and a receiver unit. All the optical units are scanned regularly so that all objects that are placed between the transmitter and the receiver will be detected. With integrated muting in every light curtain we build. Focus lowers overall project costs and reduces labor. All Focus II come standard with Fixed / Floating Blanking, Dual Transmission Channels, Range Selection, PSDI, Dual Reset and External Device Monitoring. ABB Group August 26, 2014 Slide 58

59 Safety Mats Area Guarding Applications: Area Guarding around hazardous machinery. Horizontal detection of personnel. Features: Resistant to common oils and chemicals. No Joining strips required. With or without built in ramp Ramp easily removed for joining mats ABB Group August 26, 2014 Slide 59

60 Safety Edges and Bumpers Crushing Protection Applications: Automatic door protection Moving machines / transfers Features: Safety Edges available in lengths up to 25m Safety Bumpers up to lengths of 3m Made in the USA and made to order 2 2-wire cables for a 4 wire safety circuit ABB Group August 26, 2014 Slide 60

61 Pluto Safety PLC The Heart of the System ABB Group August 26, 2014 Slide 61

62 Pluto Safety PLC s Safety System Integration with Handshaking August 26, 2014 Slide 62 Pluto is an All Supervisory Safety PLC with 20 or 46 I/O. With built in Dynamic Signals (Vital) one Pluto can monitor up to 390 devices! Each Pluto can see, execute and store the programs of all other Pluto s attached to it via the Safe CAN Bus. Hot Swap of individual units damaged in the field now only takes 7 seconds and does not require computers, programs or cables. Just a push of a button!

63 Quick Guard Fencing Machine Safety Fencing Systems Quick Guard Fencing systems are low cost, rugged extruded aluminum designs. Modular Safety Panels are ordered and shipped as complete assemblies for quick in the field installations. Engineered Systems arrive already cut, dimensioned, and with hardware premounted. No drilling, tapping or cutting when it hits your floor. ABB Group August 26, 2014 Slide 63

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