The New Machinery Directive is Here!

Five Steps to Safety

Safety doesn’t have to be complicated or confusing. Here are five steps you can take to ensure you are up-to-date with safety standards.

1) Join a standards committee.
Joining a standards committee gives you first hand knowledge of changes to standards.


2) Join an organization that provides trade shows and seminars.
By joining an organization that provides trade shows and seminars you expand your knowledge base and mindshare. Trade shows and seminars are great opportunities to not only learn about new standards but to also see new technologies available to help you meet those standards. Networking at these events also gives you the chance to utilize colleagues as sounding boards for issues or problems you may have with safety.

3) Create an internal safety committee
An internal safety committee is a great way to enforce safety regulations. Schedule monthly assessments of machinery and procedures to ensure that employees are performing duties in a safe manner. Monthly assessments also give you the opportunity to be proactive in solving issues before they become emergencies.

4) Benchmark another company that has a good safety history
By benchmarking a leader in safety you can assess your current safety policies and measures to ensure they line up with a company that has a proven track record with safety. Benchmarking allows you to see how other companies have handled similar situations and follow their lead.

5) Schedule a plant and risk assessment with an outside safety company.
Companies that perform plant and risk assessments are experts in safety. They have knowledge of the newest standards and what steps need to be taken to implement the latest regulations. When a risk assessment is performed a documented physical examination and inspection of either a single machine or an entire plant, is carried out under the guidelines of applicable national and/or international standards. Safety improvement on existing machines can be prioritized and implemented based on known risks, thereby extending the working life of the machine. Early identification of hazards on new machines will save time and money by facilitating the integration of appropriate safety measures.

A typical risk assessment includes:
• Identification of applicable standards, regulations and best industry practices.
• Statement of machine limits
• Examination of all hazards throughout the relevant machinery lifecycle phases
• Estimation and evaluation of risk
• Recommended approach for risk reduction

For more information on the issues mentioned in this article please email marketing@pilzusa.com

For more information on Pilz Services please email consulting@pilzusa.com

My company designs large machines and automated production lines. Are there new requirements to consider?

There are a number of requirements you should consider. the existing directive required that "From the main control position the operator must be able to ensure that there are no exposed persons in the danger zones" (before starting or restarting machines). Considering the risks in large machines and production lines the new directive demands the same can be achieved from all control positions. However, recognizing advances in technology the new directive introduces the obligation to consider in certain circumstances control systems and protective devices to automatically prevent start-up if it detects somebody in a danger zone.

Software for safety functions on plant and machinery.

These days, software used in mechanical engineering is not just limited to classic areas such as the programming of logic controllers (PLC) or human machine interfaces (HMI); increasingly it must also undertake safety functions.

In order to meet these requirements, safety relay manufacturers are increasingly offering freely programmable systems. Externally they are designed just like standard PLCs, but they are usually characterized by multi-channel structures. The principle of redundancy guarantees safety through cross-monitoring. Read more

The directive stipulates that:

Particular attention must be given to the following points:

• the machinery must not start unexpectedly
• the parameters of the machinery must not change in an uncontrolled way, where such change may lead to hazardous situations"

Parameter monitoring systems, such as low speed run, which through risk assessment are considered as a risk reduction measure must be implemented in accordance with appropriate devices and systems. Risk assessments must also identify normal or abnormal conditions which could lead to an unexpected start up and prevent such start up through the safety related control system.

The body plant of the future

http://www.pilzamerica.com/articles/Pilz-The-body-plant-of-the-future.pdf

How can a machine control system designer consider that "reasonably foreseeable human error during operation does not lead to hazardous situations"?

The obligation to consider 'reasonably foreseeable misuse' related not only to control systems but is reflected in the general principles of the "Essential Health and Safety Requirements". The term 'reasonably foreseeable misuse' means the use of machinery in a way not intended in the instructions for use, but which may result from readily predictable human behavior.

While similar principles are enunciated in other standards including EN ISO 12100, this statement is particularly onerous. The control system designer needs to be conscious of the risk assessment and the measures for risk reduction that are dependent on the control system. The ease ofuse and ergonomics of the machine interface and its relationship to the control system are critical. Studies show that the probability of a safety system being "bypassed" is proportional to the "benefit" of bypassing the system. Therefore to avoid predictable behavior of system bypass, the design of the safety system should be considered in a manner where machine operators do not benefit or gain incentive from bypassing safety systems. Intelligent safety concepts including zoned safety systems, boundary less guarding, safe mode enabling and safe monitoring of machine parameters should be considered by the control system designer.

What are the important changes impacting machine control systems?

The obligations on machine control system designers are more explicitly and in some cases more stringently defined. Consider the following:
"Control systems must be designed and constructed in such a way as to prevent hazardous situations from arising. Above all, they must be designed and constructed in such a way that:

• they can withstand the intended operating stresses and external influences
• a fault in the hardware or software of the control system does not lead to hazardous situations
• errors in the control system logic do not lead to hazardous situations
• reasonably foreseeable human error during operation does not lead to hazardous situations."

These requirements restate with clarity that a failure of or any other cause in a machine control system should not lead to a hazardous situation. The new wording reflects the state of the art in control system technology, where there is a distinction between software and hardware.

3D Sensor Allows for Quick Changeovers And Reduced Downtime

http://www.pilzamerica.com/articles/3D-Sensor-Allows-for-Quick-Changeovers.pdf

The approach to machinery design and the technologies used have changed significantly since 1989, how is this reflected in the requirements of the directive?

Is it true that there are many changes in the way machines are designed and constructed with increased use of electronic and software based control systems, modular construction of production lines and increased use of robotic systems. There are many changes in the essential requirements reflecting such changes particularly related to control systems and devices.

Defying the conditions

http://www.pilzamerica.com/articles/Pilz-Defying-the-conditions.pdf

One control system for safety and process functions

http://www.pilzamerica.com/articles/Pilz-Ford-PSS.pdf

How is the interaction between machine operators and machinery considered?

The consideration of the interaction between machine operator and machine is critical to safety. Ergonomics has received special attention in the new directive with a specific section laying out the requirements. There is now a strongly defined requirement on machine designers to give more consideration to this aspect of major importance to the machine operators. In this respect the safety concepts selected to reduce the risk to workers from a contact with moving parts of machinery can have a serious impact. Physical guarding may significantly impact

• how a worker interacts with a machine
• the repetitive effort used by workers
• the audible and visual sensory feedback provided to the operator

Effective risk assessment followed by the generation of intelligent safety concepts can significantly benefit the ergonomic design of machines.

The innovative PSENslock series

The innovative PSENslock series, from Pilz Automation Safety L.P. the German manufacturer of safe automation components and systems, takes safety to a new level. It operates magnetically, not mechanically, as do the more traditional systems. "The PSENslock non-contact magnetic interlocking gate switch is an outstanding alternative to traditional mechanical gate switches," said Sales Engineer Ben Harper. "It's safer because it combines secure safety gate monitoring and a non-contact magnetic interlock within the same unit. And because it's mechanically non-wearing, PSENslock has a longer service life."

PSENslock has an electro-magnetic holding force of either 500 N or 1000 N to prevent the unintentional opening of swing gates and sliding gates. Its proven transponder technology is manipulation proof because the switch and actuator are totally different items. This provides an additional measure of safety. Existing mechanical technology, on the other hand, requires the use of a keyed actuator. Consequently, it's possible that this "key" could be damaged, suggesting the door is closed, creating a potentially unsafe condition. Ideal for use in rugged industrial environments, PSENslock is easy to install. With its combination of safe position monitoring and process guard locking, it's suitable for mounting onto standard 45mm profiles around the machine.

PSENslock can be used on flap gates and safety gates and is extremely tolerant to gate misalignment. With bright, double-sided LED diagnostics on both sides; it can be mounted left or right handed. An M12 plug connection allows for simple assembly. "It's really quite an achievement," Harper added. "In addition to the longer life cycle, ease of installation, higher tolerance to alignment, and strong holding force, the PSENslock has the option to include a fully coded switch which is more difficult to defeat and can be wired in series while maintaining the high safety categories that many applications demand."

PSENslock is designed for applications up to SIL3 in accordance with EN/IEC 62061, Category 4 in accordance with EN 954-1 and protection type IP67. In terms of a complete solution, PSENslock can be connected to all Pilz evaluation devices.

Pilz manufacturers a line of safety equipment used in plants. These sensors, relays and other components can be applied as individual pieces or group components to machines throughout many industries where man and manufacturing equipment are utilized together, including automotive, robotics, packaging, amusement, and wind power. The company also provides a wide array of safety consulting services.

What new requirements impact machine instructions?

Safe operation of machinery depends on clear instructions. The obligations on machine designers to provide clear information on machine use and the hazards to be expected in operating and using machines are elaborated in detail in the new directive. The contexts of the instructions must cover not only the intended use of the machinery, but also take into account any reasonably foreseeable misuse. Other essential contents include:

• information about th eresidual risks that remain despite the inherent safe design measures, safeguarding and protective measures adopted;
• instructions on the protective measures to be taken by the user, including, where appropriate, the personal protective equipment to be provided;
• the operating method to be followed in the event of accident or breakdown and the unblocking of a machine.

A safe, clean business

Ready to go?

http://www.pilzamerica.com/articles/Pilz-Ready-to-go.pdf

How can I manage situations where there are different assessments of the same risk by different machine builders?

Machine risk assessment is part qualitative, part quantitative requiring judgment by competent persons. Consequently there is likely to be a dispersion of the results achieved by different manufacturers or their authorized representatives when carrying out a risk assessment on the same or similar equipment. With the strength of the obligation in the directive machine builders may expect that machinery buyers and statutory authorities will seek more opportunity to examine the procedures followed, the assumptions and judgments made, and the results achieved.

Additionally the demands on machine builders to provide more detailed instructions will provide traceability between Risk Assessment and Instructions.

New Pilz website has more to offer!

Whatever the reason for undertaking a formal risk assessment on machinery or work equipment, Pilz consultants can provide an impartial service. Risk assessments are encountered in almost every walk of life, even for crossing the road. But when it comes to machinery, a formal risk assessment needs certain requirements to be fulfilled, and the person performing the risk assessment must be competent to do so.

While some companies have personnel who are competent to perform formal risk assessments on machinery, others appreciate that they lack the competence and therefore need support from consultants. There are also occasions when companies are busy and do not have the resources available when required, or they may choose to use an independent service provider for this critical task.

For any of these scenarios, the consultancy division of Pilz Automation Safety L.P. can undertake risk assessments on machines or machine designs in accordance with the requirements of relevant standards. Each assessment identifies the hazards present, estimates and evaluates the risks, and determines and outlines the measures that may be applied to reduce the risks to acceptable levels.

As part of the risk assessment, the consultants identify applicable standards, regulations and best industry practices, prepare a statement of the machine’s limits, and examine all hazards throughout the relevant machine lifecycle phases.

Because Pilz consultants have decades of experience of machine safety, their advice related to risk-reduction measures is particularly useful. This is in contrast to some other consultants that can highlight problems but are unable to advise on pragmatic, cost-effective risk-reduction measures.

Furthermore, if the client requires ongoing support, Pilz can provide engineering services to take the safety concept forward, and even supply products to implement a safety-related control and monitoring system. Alternatively, the client can take the consultants’ risk assessment report and carry out the necessary work in-house or work with a third-party supplier or system integrator of their choice.

For more information on the issues mentioned in this article please email marketing@pilzusa.com

For more information on Pilz Services please email consulting@pilzusa.com

Can I demand a copy of a risk assessment from the machine builder?

Certain social partners including European trade unions lobbied for a requirement that Risk Assessments be supplied with machinery to create more transparency and to compensate for such variations in assessment. However, it is not mandatory for machine builders to provide a risk assessment.

Safe Firing:

Is it correct that there is a new requirement relating to Risk Assessment?

In the existing directive:' The manufacturer is under an obligation to assess the hazards in order to identify all of those which apply to his machine; he must then design and construct it taking account of his assessment." The term Risk Assessment was not directly used in the directive but was referred to in harmonized standards EN1050 and more recently EN ISO 14121.

The iterative process of risk assessment is now enshrined unambiguously in the directive
The manufacturer of machinery or his authorized representative must ensure that a risk assessment is carried out in order to determine the health and safety requirements which apply to the machinery. The machinery must then be designed and constructed taking into account the results of the risk assessment...
...By the iterative process of risk assessment and risk reduction referred to above, the manufacturer or his authorized representative shall: eliminate the hazards or reduce the risk associated with these hazards by application of protective measures, in order of priority established..."

Idaho National Laboratory Utilizes Pilz Automation Safety L.P. for Protection

http://www.pilzamerica.com/articles/INL-One-Page-Reference-Sheet.pdf

Are there any changes in the Essential Health and Safety requirements?

The structure of Annex 1, where the Essential Health and Safety Requirements are listed, will look familiar to those conversant with the existing directive. However, specific significant changes require careful analysis by machine builders to ensure their machines will be compliant with the new directive.

Calculated Safety: SIL Calculation in accordance with IEC 61508/61511 in process-based applications

http://www.pilzamerica.com/articles/Calculated-Safety.pdf

the New Directive?

Water Treatment Plant gets the Eco Treatment

Safe Camera System Opens New Horizons for Safety and Security

Pilz Automation Safety L.P. is opening new horizons for factory and nonfactory automation with SafetyEYE, a camera system for three-dimensional safety monitoring.  Developed by Pilz in conjunction with DaimlerChrysler, SafetyEYE places a customized, three-dimensional protective cocoon around a danger zone with a single system, which has the potential to replace a multitude of two-dimensional sensors currently in use today.  It protects, controls and monitors, and detection zones can be configured flexibly and quickly on a PC.

"Camera-based image processing will revolutionize optical sensor technology, and not only in the industrial sector," says Pilz Managing Partner Renate Pilz. "We are convinced that the SafetyEYE innovation faces an excellent future in the security sector, too."  Much more than just a sensor, SafetyEYE is the basis for a technology that safely detects objects in a three-dimensional zone and alters a robot or a machine's movement to prevent accidents. It is suitable for the widest range of industries and applications: from manufacturing operations to the tire and packaging industries, to high-bay racking systems and automatic car parks. In addition to the safety and security benefits of three-dimensional production monitor and control, SafetyEYE also can lead to increased flexibility and productivity from uninterrupted object monitoring and access guarding.

Current safety-related solutions have their limits
Looking at an example of a robot workstation comprising one or more robots and protected by safety fences, the robots generally require additional protective devices such as light grids and laser scanners in conjunction with an area limit switch. If someone enters or remains in the danger zone, these devices will detect it.  Current safety-related solutions, however, have significant disadvantages.

Optoelectronic protective devices are unable to monitor three-dimensional zones. At best they monitor two-dimensional planes. If there is no visual contact, then the workstation must also be protected using pressure-sensitive mats. Uninterrupted monitoring of a robot's operating range is only possible with a great deal of technical investment, if at all.  Another factor is that standard protective devices immediately stop the robot in the case of danger. The robot must be returned to its exact position prior to the stop in order to restart. This costs time and impacts subsequent workstations in the production line. A third aspect is the large number of different components and the complex wiring they involve. It's not only expensive to safeguard a robot workstation, but also can have a negative impact on its availability.

Joint expertise for an innovative solution
In an effort to lessen the expense and improve productivity, Pilz started to develop a new concept for zone monitoring and the safe camera system. In Sindelfingen, Germany, DaimlerChrysler's process development, automation and control technology department also was considering some new monitoring strategies. The automaker had an idea to use a combination of cameras and image-processing algorithms to enable the monitored detection zone to be reproduced in 3D and detect objects that encroached into the danger zone.

Developed at the technical image-processing laboratory at DaimlerChrysler's research center in Ulm, Germany, the same visual-assistance systems used in cars to make drivers aware of hazards, were used as the starting point.  This ideal cooperative effort had DaimlerChrysler contributing the appropriate algorithms for three-dimensional image evaluation, Pilz making the algorithms suitable for industrial use, and then developing and manufacturing the system.

One system to control, monitor and protect
The overall system is made up of three components: the sensing device, a high performance computer and a programmable safety and control system. The sensing device consists of three highly dynamic cameras that provide the image data from the zone being monitored.

The high performance computer operates as the analysis unit, receiving the camera's image data via fiber-optic cables and works out a three dimensional image using highly complex and safe algorithms. This way it is possible to observe objects three-dimensionally and to define their exact position. This information is then superimposed over the detection zones configured within the system to determine whether there has been a zone violation.

The high performance computer passes the image processing results to the PSS programmable safety and control system. With its inputs and outputs, the PSS is the interface to the machine controller and controls the whole SafetyEYE operation. If the analysis unit signals that the detection zone has been violated, the configurable outputs are shut down. Connection to the periphery also can be via the SafetyBUS p safe bus system. In future, this also will be possible via the SafetyNET p Ethernet. The detection zones and warning zones, as well as all the other parameters required to operate the safe camera system, can be set up using the configuration PC and a special software package.

Perfectly compatible safety concepts help to prevent downtime
A robot workstation that is safeguarded using SafetyEYE, for example, will be fully open in its operation. Restrictive barriers are no longer necessary. The sensing device sits above the workstation and has a complete overview of the robot's operating range. So the possibility of manipulation is excluded from the outset. One glance at the monitor shows that safety technology is at work. Color, semi-transparent cubes and cuboids – the three dimensional warning and detection zones – are superimposed onto the images from the cameras (see graphic illustrating the functional setup). The robot moves within these zone segments during its work cycle. The danger zones are defined in the form of a virtual envelope, which incorporates the warning zones and detection zones. Only objects that enter these zones are potentially at risk.

The special feature of SafetyEYE is that a detection zone violation does not automatically lead to an emergency stop. Should a worker infringe the virtual detection zone at a point that the robot would still take several seconds to reach, the control technology ensures that the robot advances at extremely reduced speed. If the worker is alerted through a warning signal and steps back, the robot will return to normal speed. There will only be an emergency stop if the worker enters the immediate danger zone. This is a clear advantage over conventional protective devices, which trigger an immediate standstill in the case of danger. With SafetyEYE processes can be precision controlled and can have flexible safeguards.

Configure warning and protection zones on the PC
Detection zones and warning zones can be combined into complex zone arrangements and are therefore easy to manage, as they can be configured quickly and intuitively on the PC. If the various operating modes on a machine require different zone arrangements, these can be switched dynamically during the machine's working cycle, via the safe bus system SafetyBUS p or via the digital inputs on the PSS programmable safety and control system. Users have flexibility because once detection zones have been defined they can be adapted at the click of a mouse in the SafetyEYE Configurator. The monitoring of detection zones is no longer based on technical needs but on the requirements of the
user's process cycles, which can be designed with the utmost flexibility.

It only takes a few hours to install SafetyEYE and configure the detection zones. To position, set up
and check conventional protective devices, on the other hand, takes at least a day. It is also more economical to use SafetyEYE. When a detection zone has been violated, an integrated diagnostic function reduces downtimes to a minimum. "So once more we can present an innovation that helps users to increase productivity and reduce costs," says Renate Pilz, Pilz's Managing Partner, getting right to the heart of the benefits of the safe camera system.

Ergonomic interaction between worker and machine
SafetyEYE also can perform standard control functions as well as monitor several independent detection zones. Not only does that lower the cost, it also reduces the number of components to a minimum. The ability to connect directly to bus systems such as SafetyBUS p and, in future SafetyNET p, brings further savings in terms of material and installation.

SafetyEYE protects plants from a bird's eye view, enabling man and machine to work together harmoniously. Requirements from the widest range of mechanical engineering applications can be implemented using the safe camera system.

Valuable objects and access to buildings firmly in view
While safety describes the protection of the environment from an object, security is concerned with protecting an object from the environment. This includes building access protection or monitoring exhibits at museums. SafetyEYE keeps valuable objects continuously in its sight because, unlike conventional protective devices, is doesn't just monitor one plane.

# # #

Can manufacturers CE mark machinery under the new Machinery Directive in advance of this date?

From the legal point of view, machinery can only be placed on the market with reference to Directive 2006/42/EC as of December 29, 2009. However, in general, the essential requirements are at least as stringent, therefore machine builders should review their products without delay and prepare to adapt them as necessary to take account of the requirements of the new Directive. Pilz provides a conformance assessment service to determine the gaps a machine manufacturer may face in bringing existing designs into compliance.

Reliable Wireless Communication for Industrial Requirements

Wireless system from Pilz, specifically for industrial requirements

Under the name InduraNET p (Industrial Radio Network), Pilz has developed a wireless system that specifically and consistently considers the requirements of an industrial environment. Users benefit from much greater flexibility and are able to implement mobile applications which would be very difficult if not impossible to achieve with a cable-based solution. A special feature of InduraNET p is the innovative antenna system with antenna diversity, which guarantees a constant, high quality wireless connection under all application conditions. Intelligent frequency management also enables coexistence with other wireless systems.

In conjunction with InduraNET p PSSuniversal offers even more opportunities for using the decentralised I/O periphery. The decentralized control platform can now be used anywhere that cable connections have reached their application limits or that long-term use of wearing communication media such as trailing cable or rotary transformers is uneconomical.

The wireless communication system InduraNET p can universally replace a cable solution, coexisting alongside other wireless services in the 2.4 GHz ISM band. It transmits with a maximum high frequency power of 100 mW. Due to its variable structure the decentralized control platform PSSuniversal can be expanded to up to 64 individual I/O modules. With InduraNET p these can now also be operated remotely from the base system. The modular PSSuniversal system can be separated at any point. All you need to do is add the relevant InduraNET p converter modules. One base station can communicate with up to four remote stations. The benefit for the user is that the view of the process I/O image remains the same.

Wireless system specifically for the industrial sector

Other WLAN-based wireless services are often used in the industrial environment for storage and logistic systems. Unlike Bluetooth wireless systems, InduraNET p does not influence any other industrial wireless systems thanks to its intelligent frequency management. In addition to the protocol mechanisms, the access mechanism "Listen before talk” guarantees that the radio channel is actually available and is not being used by other wireless services. Another characteristic of InduraNET p is its strong immunity to signals from other wireless services such as DECT, UMTS or GSM, which ensures high system availability in an industrial environment. The compact antennas enable efficient wireless communication despite strong reflections and constantly changing conditions for spreading the radio waves.

Reliable wireless technology brings benefits

With the wireless communication system InduraNET p, users have increased flexibility and freedom in the way plant and machinery is arranged. The wireless system guarantees easy accessibility within the space, something that cannot be achieved with a cable connection. All today's contact-based communication systems are restricted to linear or rotational movements. InduraNET p enables movements in all three space dimensions. This increased flexibility is also a bonus when expanding an existing control infrastructure, as there's no complex configuration or installation for the cable connections. The high availability of InduraNET p reduces downtimes as well as the work involved in unplanned maintenance work. The weaknesses in contact-based data communication, such as wear and tear on data cables and sliding contacts, are irrelevant with wireless communication. Radio-based communication also helps to save costs, as the work normally involved in planning, installation and maintenance of cable-based solutions is no longer required. This is particularly significant on mobile applications, as contact-based communication often requires special solutions using cable drag chains or rotary transformers, for example. By implementing InduraNET p into the PSSuniversal centralised control platform, Pilz is presenting to the market the first step towards an industry-compatible wireless technology. 

Is there a transition period for application of Directive 2006/42/EC?

In general, there is no transition period, in the sense of a period during which both the current Machinery Directive and the new Machinery Directive are applicable. The provisions of the Directive 2006/42/EC become applicable December 29, 2009.

How will the new machinery directive be enforced?

Freedom of movement of machinery is guaranteed with the "passport of the CE mark". As most machines are placed on the market without independent certification by notified bodies, surveillance is essential to the fair and effective operation of the single market for the supply of machinery. Directive 98/37 dopes not use the term "market surveillance". However, in the new MD the framework for market surveillance is now clearly stated ina new Article 4 specifically dealing with this aspect.

• member states must take measures against non-complying products
• there must be a known national competent authority
• tasks and powers of such authority must be clearly defined and transparent

Properly applied, this strengthening of the "policing" aspects will ensure a fair market place with a high standard of safety. In addition, such authorities in each member state are obliged to consider machines that may be unsafe when used for their intended purpose but also machines that could be unsafe "under conditions which can reasonably be foreseen".

Click to view Trends and Developments of HMIs

http://www.pilzamerica.com/articles/Trends-and-DevelopmentsofHMIs.pdf

Buhler Inc. and Pilz Automation Safety L.P. Partner for Safety

(CANTON, MI) – Buhler Inc. of Plymouth, Minn. has partnered with Pilz Automation Safety L.P. of Canton, Mich. to implement safety in its flour heat treatment, brewing and malting equipment. Buhler Inc. installed PNOZmulti modular safety systems to control explosion vents and emergency stops. This system will protect personnel and equipment from being harmed or destroyed during a deflagration. The PNOZmulti m1p allows for easy expansion as well as an improved response time of approximately 40ms. Download PDF Reference: http://www.pilzamerica.com/articles/INL … -Sheet.pdf

Pilz Automation Safety L.P.

The world leader is SAFE automation; Pilz offers a full range of leading-edge safe automation products and services. The company’s innovative technologies and safety expertise provides customers with the leanest and safest solutions.

Buhler Inc.

Buhler is a global leader in the supply of process technology, especially production technologies for making foods and engineering materials. Buhler is active in over 140 countries and has some 7000 employees worldwide. In fiscal 2008, the Group generated sales of CHF 1893 million.

My company receives machinery from our parent company in the USA. What are the implications of the new machinery directive?

You need to ensure that the machine conforms to all applicable directives including the new machinery directive. Additionally, you need to designate a person established in the community to be responsible for the compilation of the technical construction file. This could be a competent person in your own organization or a third party you appoint.

Calculations without the headache Software tool verifies the functional safety of protection devices on machinery

Canton, MI – Pilz Automation Safety’s software tool, PAScal, verifies the functional
safety of protection devices on machinery in light of current standards. The Safety
Calculator supports manufacturers in the calculation of failure limit values, as required by
standards IEC 62061 and prEN ISO 13849-1. The software tool enables a reduction in
costs and the amount of time spent on the task, particularly as figures need to be
recalculated each time the safety functions are modified.
The PAScal Safety Calculator separates the safety functions into their component parts,
calculates the overall probability of a dangerous failure per hour (PFHD value) and
verifies the data with the prescribed performance level or safety integrity level. The
software tool also takes into account potential architectures and variations if subcomponents
are connected together and parameterized.

Division into sub-systems
According to the approach of IEC 62061 (sector standard from IEC 61508 for safety in
machine control systems), safety-related functions are divided into sub-systems such as
sensors, inputs, logic, outputs and actuators. So the architecture for each sub-system can
be specified separately. The sub-systems can be combined as required.The Safety Calculator not only considers the factors listed in prEN ISO 13849-1 for
evaluating the common cause failure (CCF), but also takes into account the parameters
that depend on logic or electronics, which affect diagnostic coverage (DC). These include
detection of shorts between contacts or synchronicity monitoring on multi-channel
sensors, for example.

Based on a database
The basis for the Safety Calculator is a comprehensive database that already contains
details of Pilz products. Users can also define their own components and store them in the
database, provided the necessary numeric values are known. The Safety Calculator uses
this data to calculate the PFHD value.
The PAScal Safety Calculator provides support to manufacturers when designing safetyrelated
control elements. For new design procedures are required now that EN 954-1 has
been replaced by prEN ISO 13849-1 for the design of safety-related control systems and
standard IEC 62061 has been published.
The software tool also allows for the flexibility that engineering requires. Safety
functions can change from machine to machine, so that calculations need reworking
again and again. The Safety Calculator absorbs the associated costs.

What is an authorized representative?

The machinery directive anticipates that machine builders may require appointing competent persons to carry out some or all of the administrative and assessment procedures required to CE mark a machine. The new machinery directive defines an authorize representative as "...any natural or legal person established in the Community who has received a written mandate from the manufacturer to perform on his behalf all or part of the obligations and formalities connected with this directive..."

New Profinet Interface Proves Impressive

Pilz decentralized I/O system, PSSuniversal, used in the automotive industry Pilz is to be the exclusive supplier of decentralized I/O periphery with protection type IP20 to automotive manufacturer BMW, effective immediately. In the future, the automotive group will use the PSSuniversal decentralized I/O system worldwide.

A prerequisite was the development of a new head module with Profinet interface, which was achieved in close cooperation with BMW. This was an impressive control solution from both a technical and an economic point of view. Thanks to the customized, certified Profinet interface, the decentralized I/O system PSSuniversal can be integrated seamlessly and safely into existing or new plant structures. “We regard the openness of control solutions not just in terms of investment protection. We are really keen to give users the chance to choose the solution that best suits their project”, says Albrecht Feucht, from Key Account Automotive at Pilz.

Open systems stimulate competition Under the scope of AIDA (Automotive Initiative of German Domestic Automobile Manufacturers), German automotive manufacturers have opted to use Profinet as a standardized communication medium, but AIDA has also stated that competition needs to be guaranteed where the connected control solution is concerned.

The decision in favor of Pilz was preceded by a comprehensive evaluation of the market and all available products by experts from BMW. In addition to its openness toward Profinet, other criteria included the system’s cost effectiveness plus the ability to link standard control functions and safety functions. Intense cooperation and continual coordination with BMW during the two-year development period paved the way for the launch of a user friendly system which meets the exact requirements. System is easy to handle. The integrated safety principle of the PSSuniversal represents a key distinguishing feature in comparison with existing solutions.

On the control system, the head module alone represents the safety-related subscribers, so that users only need to make the necessary settings at this central point. There is no need to assign awkward sub-addresses. Consequently all safety-related addresses on the Profinet Master can be put to optimal use.

Not only does this reduce the administrative work in assigning safe address ranges, it also
reduces costs, as less hardware is needed because the safety technology is concentrated
exclusively in the head module.

Initial projects with the decentralized I/O system Pilz PSSuniversal with Profinet connection will be implemented in BMW’s plants in Regensburg, Munich and Leipzig, with global applications to follow.

If my company is located outside the EU how will they meet this requirement?

For machine builders without an operation in the EU the most effective means of meeting this requirement is to appoint an "authorized representative".

What does “established in the community” mean?

To be established in the community, the person or company must be carrying out a lawful economic activity on a stable and continuous basis in a Member State of the EEA.

Making Halloween Lean

Halloween Lean?

Incase you haven’t heard, Lean is in. So we at Pilz wondered if there was a way to apply lean to Halloween. Here’s what Vito Curcuru, our Marketing Manager came up with.

It has been a while since I trick or treated and a lot has changed, but it’s not too late for you to teach lean to a kid! Since these tips involve maximizing candy consumption, it’s probably best to teach this lesson to your nieces and nephews or friend’s kids.

Value Stream Map that route! Look back at last year’s path.  Were some houses better than others? Should you skip the bad ones?  Do you have any relatives who live close by who you can visit 2x or 3x? Did someone in your group slow you down? Is there a local mall with stores giving out candy?

5S that Candy Pile

• Sort out the bad candy
• Straighten the piles-gum in one, ‘good candy’ in another-you get the idea.
• Sweep out those wrappers-you shouldn’t have been eating as you were trick or treating-see VSM step above-but it is Candy time-so you are forgiven.
• Standardize-figure out where the candy sh ould go and mark it off-put that ‘good candy’ in a place your parents and siblings won’t find it, get the ‘bad candy’ in a place siblings and parents can see it-so they only take the bad stuff.  Put gum in a place at home and do not let it get in your school bag-teachers will confiscate it!
• Sustain-don’t mix the piles, find where your parents and siblings keep their candy and replenish your stock.

Must machine builders set up operations in Europe to comply with the new requirements?

The single market is a free market and provides no barriers to suppliers from outside the EU from placing their products on the market. However, there is an important change in the procedures for machine manufacturers exporting into Europe. Such machine builders must identify the person, established in the community, authorized to compile the technical file for the machine.

Planning on going to a Halloween party...

Planning on going to a Halloween party this year, but just can’t stand the thought of not being home to give kids candy? Automate your candy dispensing and decorations with Pilz products.

Mount SafetyEYE® over front door. Program zones so that as the kids move they trigger spooky sounds. Bonus: SafetyEYE® takes snapshots of faults, so you’ll still get to see the kids all dressed up.

Instead of using wooden fencing around your spooky Halloween graveyard, use PSENopt light curtains.

Use the PNOZm3p multi for burner management to control fire under a cauldron or to create a devilish scene complete with fire and brimstone.

Program a touchscreen PMI so kids can make their candy selection. Use the PNOZsigma relay to control the distribution of the candy through chutes.

These are just a few of our ideas; we’d love to hear how you would automate your Halloween decorations and candy distribution.

Overall motion management

Motion control system controls and automates packaging machines
Packaging machines in the pharmaceutical sector are demanding: they have to be reliable, modular and versatile, but most of all they have to be flexible and efficient. The requirements of the corresponding drive and automation system are equally high. Pilz motion control manages the movement of all the servo axes to ensure that complex workflows from infeed to cartoning do not fall out of sync and so that products can be switched at the touch of a button.

With impressive speed and the rhythmic sounds of all these simultaneous processes, foil-packaged tablets stream out of the machine on four channels at once. The machine operation is fully automatic; the actual packaging process is barely visible to the eye. Within seconds, knives transform the endless sheets into manageable sizes, which then find their way into standard cartons with the package inserts included.

Tablets in the morning, maybe capsules in the afternoon, but both need to be sealed on the same machine. Packaging on pharmaceutical products calls for innovative concepts, the wide range of products and packaging sizes demand flexible solutions. Stored process parameters mean that packaging machines can be changed over quickly at the touch of a button, guaranteeing cost effectiveness. Each system must be modular and easily expandable according to need; what’s more, only those plant sections that are currently in use should be active.

As a subsidiary of the international company Romaco-Pharmatechnik GmbH, Romaco develops packaging machines specifically for the pharmaceutical industry. Part of the product portfolio of the Karlsruhe, Germany-based company includes heat sealing machines, which seal pharmaceutical products in film so that they are air and moisture-tight and provide a perfect fit for the relevant shape. The company offers a flexible selection of machinery covering a wide range of functions in accordance with individual customer requirements.

A key component of a versatile packaging machine designed for a variety of tasks is a sealing roller with an asynchronous motor, which sets the timing for all subsequent axes via incremental encoders. A conveyor system feeds in the product for packaging, which is then inserted synchronously into the sealing roller. The heated sealing rollers take the liner material from rollers on both sides, forming an airtight enclosure around the pharmaceutical product. Servo motors drive the axes on a packaging machine. They guarantee a rapid reaction to changing process parameters and therefore a high degree of flexibility in production. 

Pilz motion control (PMC) is responsible for the reliable, synchronous, fully automatic control and coordination of the individual drive axes and motion elements on the heat sealing machines. Precision is the trump card.  For example, the intelligent control and automation solution ensures that the imprint on a pre-printed seal is always positioned in the middle of the tablet pack, or that the lengthways and crossways cut on the packaged product always separates exactly in the middle of two tablets, and that the perforation blade puts the tear line needed to separate individual tablets exactly where it belongs, to within a tenth of a millimeter. Any variations in dimension due to varying fill quantities are adjusted automatically by the controller during operation. “The automation system manages all the movements of a large number of physically separate servo axes within a plant or application”, explains Harald Dietel, Head of Product Management at Pilz. In addition to the original motion control tasks the system also undertakes the machine’s automation in conjunction with the integrated PLC.

There are two different types available: You can either employ the drive-integrated PMCprimo Drive (up to nine axes) or the controller-based PMCprimo 16+ (up to over 100 axes), depending on the number of axes used. PMCprimo Drive is integrated directly within the motor amplifier and can incorporate up to eight additional drives. At the same time it performs the task of a central controller. In this configuration the system contains everything required for the complete automation of small or medium-sized machinery, such as the packaging machine described above. PMCprimo Drive works economically right from the first axis; it reduces the amount of wiring involved and saves space within the control cabinet. If you need to control more than nine axes or larger plants, the PMCprimo 16+ is the system to choose as a central controller. It can be used to implement complex motion and control functions with well over 100 axes. Servo amplifiers, servo motors, panels and many other components required for automation technology help to round off the system.

Whether you are planning a new design or a retrofit for your machine, whether you want a small machine or need whole packaging lines equipped with infeed, packer, cartoning station, palletizer or pick-and-place: both the drive and controller based solutions offer the optimum hardware basis for any application. Pilz motion control is expandable, remaining open and flexible to developments of any type. Both versions have something in common: less work is required during implementation and programming. Numerous function blocks for automating axis movement are available and ready to use. To activate functions such as “cross cutting” for example, just start this up from the menu and set reasonable parameters. The system will detect any implausible combinations and not allow them.

There was a whole range of reasons why Romaco Siebler opted for Pilz motion control for their heat sealing machines.  “Simplicity and expandability were the convincing arguments. Because of the large number of compatible functions, it took hardly any effort to implement the entire system, and that includes parameter setting and diagnostics”, stressed Martin Schneider, electrical design engineer at Romaco Pharmatechnik GmbH in Karlsruhe. Selection was made even easier by the compact design and the fact that both control and automation functions are included in one system and are from one source. “Competent advice and project backing convinced us that we made the right decision” added Jürgen Kratzmeier, Technical Manager at Romaco Pharmatechnik GmbH.

Pilz wants to go one step further in the future: The plan for the next controller generation is that it should combine the various requirements of standard control technology, safety technology and motion control in one system.

Pilz is a global company, as such, not all standards and information will be applicable worldwide. Please check with your local Pilz office to ensure your factory and/or machines meet local standards.

Fast, precise and safe

Proven safety technology for flow wrapping machinexs

Whether it’s powder, liquid or solid: many products cut a better figure in a plastic pouch. Flow wrapping machines not only seal a wide range of products, they also persuade through a whole assortment of attractive pouch types. The machines work quickly and reliably, can be converted to new tasks in no time at all and take up very little space. Pilz safety technology ensures there's no conflict between productivity and safety.

With impressive speed the machine pulls the plastic web over several guide rollers and on to the forming shoulder: it is here that the film web is made into a tube package, which can be filled with pieced, powder, paste, granulated or liquid products as required. A discharge belt pulls the wrap down along the wall of the filling tube, the longitudinal sealing tool seals the film tube vertically. Once filled, the transverse sealing tool seals the packaging horizontally and the blade separates the bags. The benefits of flow wrapping: It can be adapted to suit almost any packaged product perfectly, it enables vacuum packaging and, because the film is transparent, the type and quality of the contents is clearly visible. Whether you need a stand-up, flat or side-sealed pouch: flow wrapping machines can now handle an impressive variety of shapes and solutions.
Rovema Verpackungsmaschinen GmbH is based in Germany and offers a wide range of packaging and cartoning machines for the most wide-ranging products and application areas. The Rovema Group has branches worldwide and currently employs around 700 staff. Flow wrapping machines are a key component in the Rovema portfolio. “The demand today is for intelligent packaging solutions which set standards and are based on the respective requirements at the point of sale. At the same time they must be economical and future-proof", says Walter Maurer, who is responsible for electrical design and standardisation at Rovema.

Perfect packaging in the shortest possible time
The medium-sized company supplies intermittent horizontal/vertical, continuous vertical and double axis flow wrapping machines with a linear motor. The machines are always modular and open for future tasks and trend changes.  All the flow wrapping machines have compact dimensions and can be operated in stand-alone mode as well as in a network with other plant and machinery.

As shown, the packaging material on the VPL flow wrapping machine is fed from rollers and the machine operates vertically: The product to be packaged is fed in to the bag via a collection container and down-tube; the filling, sealing and separating process runs continuously. A non-wearing linear motor is the main drive for the transverse sealing station. Some of the outstanding features of the VPL flow wrapping machine include: its wide format range with high performance, the ability to store individual production programs, freely programmable sealing times and high sealing pressures, plus the vacuum film draw down unit which guarantees consistent bag lengths even with extremely thin films (from 20 µm). The high pressure of the transverse sealing tools means that the sealed seams are especially tight. The use of special magnesium alloys for moving parts minimises the mass moment of inertia and increases output. If necessary it is also easy to integrate additional features such as pulse welding, a zip strip applicator for producing re-closable bags, edge profiling and online diagnostics via modem.

Safe, efficient processes
High availability and highly automated processes require an efficient safety management in the background, which will not only exclude any risk to operators in the event of a fault but will also prevent serious damage to the machine. However, safety-related equipment must not work to the detriment of productivity. In other words: safety technology is intended to protect the operator from injury, but must not obstruct him in his work any more than is necessary. In issues concerning safety, Pilz has enjoyed an excellent reputation in the mechanical engineering sector for many years.  “We choose Pilz because the company is the recognised manufacturer for safety technology on the market. That’s why our machines only leave this factory fitted with Pilz safety solutions”, stresses Walter Maurer. As with all their other flow wrapping machines, the VPL is fitted with PNOZ safety relays. When these are operated, the machine comes to an immediate stop.  Non-contact electromagnetic safety switches PSENmag monitor the sliding gates and covers to ensure they are securely locked, the safety relays evaluate the signals. Should an operator open one of the access gates during the filling phase, the machine will immediately switch to a safe condition.

Rovema can now look back on fifteen years of co-operation with the safety specialists from Ostfildern near Stuttgart. One of the reasons for the successful business partnership is that the development of new packaging solutions always goes hand in hand with the integration of modern safety solutions. When it comes to new and continuing developments, Pilz is one of the first at the table as a partner for safety. “Our partnership is characterised by the quality and reliability of the products, the expertise of Pilz's external sales engineers and, finally, trusting co-operation", says Walter Maurer, summing up. An excellent basis for some good business in the future.

Our company currently uses the procedure of sending a technical file for review and retention by a notified body. What options do we have?

This specific procedure will no longer exist under the new Directive. Beginning December 29, 2009, manufacturers of products placed on the market on the basis of these procedures will have to apply one of the procedures set out in the new Directive 2006/42/EC. For machines manufactured in accordance with harmonized standards that cover all the relevant health and safety requirements and are competently assessed, the manufacturer will be able to certify the conformity of the product him/herself.

Are there changes to the procedures for establishing #conformance?

Both the existing and new directives provide for stricter conformance assessment procedures for specific categories of highly hazardous machines listed in Annex IV of the directive. For such machines self-certification is now possible when harmonized standards are fully applied. It will no longer be possible for manufacturers of machines to provide a Technical Construction File to a Notified Body for review and retention. An additional assessment process assuring conformance through inspection and quality assurance is provided.

Quick, but gentle

Automating a confectionery packaging machine

Chocolate products place heavy demands on packaging machine manufacturers. Speed and flexibility need to be combined with gentle handling. The Italian company Fima specialises in the packaging of confectionery products. To make sure that the machines “stay in time” and that the individual modules are perfectly synchronized, the company uses Pilz motion control; not only does it control the automation and drives reliably and flexibly, it’s easy to handle too.

Ever decreasing loads, frequent product changes and rapid time-to-market – these are the challenges that chocolate product manufacturers face. Fima, which is based in Bologna, belongs to the OPM Group and is famous for its innovative packaging machines, predominantly for the confectionery industry. Although the company operates internationally, it sells most of its machines into Germany, for that’s where there is a huge demand for gentle product handling and a high level of flexibility.

Modular concept for packaging chocolates 

Fima’s “Sweet Magic HF” (Hollow Figures) wrapping machine can handle several different wrapping styles for chocolate pralines – from envelope style to single and double twist wrapping, through to hollow figure wrapping.

The machine has a belt conveyor with ready-made molds corresponding to the product to be wrapped; it also has an integrated, automatic product infeed.

Like all Fima’s machines it has a modular design, in other words, it can be broken down into functional blocks, made up of individual modules or an electromechanical component.

• The “infeed” module consists of a belt conveyor containing product-specific molds, which feeds the products on to the turntable.
• Paper handling: Electromechanical component to unwind, cut and position the foil on the product
• Turntable: Carousel with eight stations, which divides the folding processes into individual steps. Each folding step is undertaken by a specific wrapping module;
• Wrapping module: Each of these modules performs a specific wrapping step;
• Belt module: Used for products that have additional braiding;
• Pick and place: Feeds the machine. The products are picked from a transport plate and placed on the belt conveyor. The products are picked up using suction caps.

Special configuration features

The various modules are very easily accessible for a rapid format change. This is also an advantage for the machine’s maintenance and cleaning requirements, particularly in view of the fact that all the modules are self supporting, i.e. dirt drops off as soon as the module is removed.

To switch the format, or the product, all the operator has to do is exchange the wrapping module for the respective packaging type, the product-specific belt conveyor and the turntable. The remaining adjustments for the new format are made automatically when switching to a new recipe.

All the servo motors are linked to the movement of the turntable via electrical cams. The cams are defined via the stored recipes, and all the machine’s movements are finely coordinated in the process. All the adjustments for new products result from the recipe selection made on the operator terminal. The pick-and-place station is not a separate part of the machine, as is often the case, but receives the data from the same recipe data set. This means it’s possible to undergo a complete format or product change in around 30 minutes, including all the mechanical modifications.

Particular attention was paid to special functions on the machine, to counteract material waste. Thanks to the “No product, no packing material” function, the wrapping material is only unwound and drawn into the machine when the product is actually present.

High-level performance

The machine’s flexibility was achieved thanks to the versatility of the motion control system PMCprimo Drive, which is employed in these machines. This enables the operator to optimize the synchronization of the individual axes at any time.

The “Sweet Magic HF” uses five Pilz servo motors, which are automated via the drive-integrated control system PMCprimo Drive. As no space is required for a separate controller, it’s also possible to save space in the control cabinet. With the development of the PMCprimo Drive it was finally possible to meet the various requirements of the packaging machine manufacturers. Fima in particular was able to increase the efficiency of its machines demonstrably.  Optimum packaging is achieved thanks to the ability to detect the exact position of both the product and the wrapping material.

Also, the control system can react quickly to changes by optimizing a series of pre-defined parameters.
In terms of the software, all functions are implemented using ready-made program modules in accordance with IEC61131-3; all that’s needed is to set the parameters. So the programming of complex functions is reduced to a minimum. Another feature of the control system that Fima values very highly is the ability to use all the digital outputs on the PMCprimo Drive as digital cams. This means that the status of the outputs depends on the respective axis position. So fast reaction times are guaranteed and the solenoid valves in the machine are reliably controlled.

Both Pilz and Fima are convinced that they have taken the right course in terms of satisfying the rapid changes in market requirements.  This can be achieved through machines with minimum set-up times, which guarantee high plant availability. Not forgetting the flexibility of a modern machine, which enables an immediate reaction to trends and special requests.

Pilz has been a motion control partner of Fima for many years; with the PMC product series (Pilz Motion Control) and all its possibilities, it has contributed to the success that the packaging machines have enjoyed.

Solutions for the packaging industry

Pilz combines the issues of safety, automation and motion control. From sensor technology and the corresponding evaluation devices with diagnostics and visualization, through to actuator technology: Pilz can implement universal solutions. The packaging sector is keen to increase quantities and the number of product types. This is where Pilz can point to new horizons. Many Pilz products are designed to meet the specific needs of the industry.   For example, PSEN safety switches take into account the industry’s strict hygiene requirements by being resistant to cleaning agents. The range of PMI operator terminals also includes units with approval to be used in flammable and explosive environments. Excellent recipe management is also provided, so that rapid format changes can be supported.

Pilz is a global company, as such, not all standards and information will be applicable worldwide. Please check with your local Pilz office to ensure your factory and/or machines meet local standards.

Are machines like printers and other office equipment included in the #MachineryDirective?

The existing machinery directive excluded machines where the hazard sources were primarily electrical as these could be CE marked under the Low Voltage Directive (LVD). The interpretation of the LVD and the existing Machinery Directive, resulted in the unintentional exclusion from the machinery directive of machines on which it could be claimed that the hazards were primarily electrical. In certain cases such an interpretation resulted in only the LVD being applied. This loophole is now closed by specifically listing in the new Machinery Directive the electrical and electronic products which are covered by the LVD as opposed to the new Machinery Directive. They include:
·    Household appliances intended for domestic use
·    Audio and video equipment
·    Information technology equipment
·    Ordinary office machinery
·    Low-voltage switch gear and control gear
·    Electric motors
·    Switch gear, control-gear and transformers
Machinery builders making products not covered by the above exclusions and who previously elected to apply the LVD will not have to apply the new Machinery Directive as well as the LVD.

Safe Interaction Between Man and Machine

Modern safety and control concept leads to greater productivity

Faster, more flexible, safer – with this objective in mind, the level of automation on plant and machinery continues to advance in all industries. Both safety and control technology take these high requirements into account. If necessary, powerful components can be combined to form complete systems, which guarantee safety on the one hand, and can increase productivity on the other. If the user can adapt technology to suit his requirements, then he has a cost-effective, tailor-made solution.

In many industries, packing is still associated with manual work. Where man and machine work together, the risk of injury must be minimized to the greatest possible extent. Safety devices used to be viewed as obstructive and inconvenient, but today the opposite is true: modern safety and control concepts make handling easier, and plant and machinery more productive.

Faster thanks to the new safety concept
The semi-automatic vacuum-packing machine feeds in the bottom foil via a roller; it is then transported via a chain drive. The foil is brought up to temperature in the forming chamber; a special compressed air/forming procedure and the appropriate tool are used to create the desired tray shape for each packaged product. Staff use both hands to insert grilled sausages into the tray-shaped plastic film, six pieces per row and per pack, before the conveyor moves on and another set emerges from the forming station. After the filling station comes the sealing station: The top film seal is fed through a second roller; a vacuum pump extracts the air and thereby the oxygen. This slows down the activity of the micro-organisms, while the inflow of nitrogen prevents the sausage slices from sticking together. Finally, the top and bottom film layers are impulse sealed under pressure in the sealing chamber. The product packaging is now secure and durable. At the machine outfeed, longitudinal and transverse cutters separate the packaged product into individual trays, which are then fed into transport crates via conveyor. Two coils wind up the residual film cut from both sides.

Sprinter is the name of the latest development from Komet, manufacturer of semi and fully automatic vacuum packaging machines. The company is based in Plochingen, Germany, and has its roots in the butchers’ trade. It’s in this field in particular that Komet’s table-top units are used, as they provide an airtight seal for everything that needs to be kept fresh and preserved. Even in the butchers’ industry there appears to be an irresistible trend away from the skilled producer and towards industrial production; customers increasingly ask for ready-packed goods, so Komet is increasingly focusing on semi and fully automatic machinery. Flexible and quick to convert, they can pack items in up to eight parallel trays, depending on the packaged product and the size, with or without automatic infeed. Even non-food goods can be packaged and sealed efficiently using automated packaging machines.
Another reason why the machine is called Sprint is because, in comparison to the previous model Quickvac 2000, it can convey products to their packaging more quickly, using a less complicated procedure. That’s because of a modern safety and control concept, which Pilz developed for Komet.

Designed for maximum compatibility: sensor technology, evaluation device and visualization on the Sprinter, the multifunctional safety system PNOZmulti configures simpler, safer interaction between man and machine. The safety system has a modular structure and can be used flexibly to suit the application. Instead of wiring, the user configures the needed functions simply, in a configuration tool. This saves time, space and money because there is no longer any complex individual wiring and all the safety-related functions are located in one housing. PNOZmulti is cost effective when monitoring four or more safety functions and can also undertake standard control tasks.

By comparison the safety devices on its predecessor were simplistic and mainly based on individually wired switches and contactors. Large covers safeguarded wide-ranging potential danger zones such as the forming and sealing stations via switch contacts. The infeed area in between was narrow and only allowed a one-up arrangement.

On the Sprinter, the cover on the forming station is reduced to a minimum. Instead, an advance security slide ensures that it is impossible to reach into either the forming or the sealing station from the filling station. If the slide switch is not closed, the safety system will prevent the bottom film from being formed and stop pressing and heat-sealing in the sealing station. Propulsion drives and valves are switched off; the central PMI operator terminal (Pilz Machine Interface) receives an error message, stating the cause and the source.

Magnetic safety switches, PSENmag, monitor the mobile protective hood over the sealing station, the longitudinal and transverse cutters, and the lower positions of the lift cylinder plus the security slide on the forming/sealing station. The PNOZmulti also monitors the E-STOP and the enablers that control the heaters and valves (pneumatic + hydraulic). The risk of injury from the packaging machine, therefore, is kept to a minimum, both during operation and in setup mode. “With PNOZmulti the machine has a flexible safety concept which is really easy to adapt to our requirements. Now the infeed area has a three-up arrangement, so assembly is quicker and easier, plus the machine is more productive“, says Harald Janke, Technical Manager at Komet.

Solution for safety and standard
A modern control solution also fell within the scope of the cooperation between Komet and Pilz. The standard control technology on the Sprinter also comes in useful for automatic operation and setup mode. “People at Komet were unhappy with the existing control solution and were looking for an efficient alternative”, recalls Ralf Kessler, Applications Engineer at Pilz. Now they are using a PMI operator terminal in conjunction with a Profibus Master. A soft PLC runs under the Windows CE operating system. The standard I/O modules are logged and controlled via the PSSuniversal. The Pilz centralized control platform covers the whole I/O periphery as one system and is universally applicable. Users have three options: pure safety applications, combined safety and standard applications or exclusively conventional/standard control functions. With the grey, standard head modules it is possible to use analog and digital standard inputs and outputs on the fieldbus systems, without a functional connection to the safety technology.
On the Sprinter, the head module of the PSSuniversal is also connected to the PMI via Profibus-DP, just like the PNOZmulti. Due to the system’s modular design, the PSSuniversal can be individually adapted specifically to meet the respective requirement. If any adaptations are required, modules can simply be expanded or exchanged.

Benefitting from expertise
Pilz was also contracted to complete the electrical design, prepare the circuit diagrams and carry out the programming, including commissioning.
“As a small company with around 30 staff we are reliant on competent, reliable partners for our electrical design and programming; we need partners who know what’s happening and know what’s important to us”, says Janke, “Here we found Pilz to be a suitable partner, their technical advice was superb and the collaboration with the Pilz staff ran smoothly.”

The competence of Komet in terms of automation technology, combined with Pilz’s expertise in matters of control technology and safety, jointly produced a new vacuum packing machine that operates more productively and is therefore of greater value.


Pilz is a global company, as such, not all standards and information will be applicable worldwide. Please check with your local Pilz office to ensure your factory and/or machines meet local standards.

Q. Why are partly completed machines treated differently in the #MachineryDirective?

A. Partly completed machines are the only category of machine to which all the obligations under the directive do not apply. That is because it may not be possible for a "partly completed machine” to fully comply until it is incorporated into the end machine. Consequently there is a newly defined specific procedure for "partly completed machines" requiring that:

the assembly instructions for partly completed machinery must contain a description of the conditions which must be met with a view to correct incorporation in the final machinery so as not to compromise safety and health.
The declaration of incorporation must include:

a sentence declaring which essential requirements of this Directive are applied and fulfilled...and, where appropriate, a sentence declaring the conformity of the partly completed machine with other relevant Directives.
a statement that the partly completed machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with the provisions of this Directive, where appropriate.

Manufacturers of partly completed machines will need to implement the prescribed procedures. The objective is to provide security to machinery builders and users in relation to the obligations on manufacturers of partly built machines, while providing clarity on the safe integration of such products in machines or assemblies of machines.

Packaging and Safety: What You Can Do to Protect Employees

Machine builders and Original Equipment Manufacturers (OEM’s) are being challenged to incorporate additional automation and/or motion into their machinery to address the flexibility demands of the packaging industry. These flexibility demands can create complex safety issues into the packaging machinery, but rest assured, there are solutions out there that unite flexibility and ensure the safety of machine operators.

Shorter innovation cycles and increased pressure from the competition is driving the need for more flexible packaging machines. This demand has resulted in the decrease of batch build and multi pack runs and now requires your machinery to produce multiple packaging variations from the same machine. This flexibility must include the ability to perform quick product changeovers while maintaining a high level of throughput efficiency.

With flexibility in mind, the question is; “What is the impact to my machine and operator safety?” This reality has driven the industry to look into alternative solutions not only produce their product in a flexible manner, but at a faster rate as well. Automation coupled with motion control has provided the packaging industry with this flexibility. However, an increase in motion requires a robust safety system to monitor and control the additional moving components. For example, these safety systems must meet industry standards, will require multiple axis controllers and other motion control products to allow safety processes to run quickly and precisely. When these products are deployed properly you will achieve the required flexibility and observe an increase in the throughput of your products.

It is vitally important to ensure safety when adding motion into your packaging machines. When looking for motion control products look for: synchronization of a wide range of decentralized drives, motion control to manage the movement of highly dynamic drives, camshafts for a wide range of additional functions, manufacturing at consistent quality and low cost, quick to set up and maximum flexibility, automatic adjustment to product variances and handling and robotics as an integral part of a complete automation solution

Motion control products should include: PLC to control the machine, motion control for optimum movement management on decentralized drives, individual safety solution tailored to your needs and universal, integrated software and tools.

Packaging specific applications, motion control components should include: open for individual requirements, unite safety and standards, have safety integrated within the drive, ensure every law of motion is available, and use real or virtual master axes and tools adapted to suit the task of the packaging machine

Control solution should also be platform-independent: Integrated soft PLC in accordance with IEC 61131-2, fast scan time from < 50us for 1000 instructions No adjustments required to change platform, all of the automation in one project, support for modular structures, large selection of field buses, extensive libraries, motion control, interpolation and OPC Server.

Comprehensive motion control functionality should include: virtual main shaft, cam synchronization, integral “flexible cam”, register control, web tension control, linear and circular interpolation, electronic camshaft and safe motion within the drive.

With the “what to look for” criteria checklist in mind, the next question to be asked is who is a competent and experienced supplier of motion control products?

Pilz offers The PMCprimo drive provides machine’s flexibility by enabling the operator to optimize the synchronization of the individual axes at any time and allows the use of multiple Pilz servo motors that are automated via this drive-integrated control system. Therefore, not requiring additional space for a separate controller and saving valuable space within the control cabinet.

Adding motion to your machine may be as simple as adding light curtains and relays, but it is important to recognize that there are proven motion solutions available that address the industry demands of flexible and ensure the safety of packaging machinery.

#B11.TR3 Risk Assessment

B11.TR3 highlights the need for risk assessment and the role of risk assessment in machinery safety. It also provides manufacturers and users of machinery a method to analyze and reduce risks associated with hazards generated by machines. It also gives an approach to risk assessment and risk reduction that will allow tolerable risk levels to be achieved.

Q. What is "partly completed machinery"?

A. A partly completed assembly"...means an assembly which is almost machinery but which cannot in itself perform a specific application. Partly completed machinery is only intended to be incorporated into or assembled with other machinery...thereby forming machinery to which this Directive applies." A robot without jigs and fixture and a welding head may be considered "partly completed machinery." When assembled together as in a robotic welding cell, the assembly becomes a machine.

Manufacturers of "partly completed machines" are required to follow specific CE marking procedures related to the nature of their machinery as opposed to a completed machine. Placing a CE marking on a partly completed machine is not allowed.

#ISO 13849 Safety of Machinery- Safety-related parts of control systems.

Type B-1 standard. Safety-related parts of control systems (SRP/CS) are parts of the control system assigned to provide safety functions. The Ability of SRP/CS to provide safety functions is allocated one of five performance levels (PL). They are B, 1, 2, 3 and 4. This standard provides a methodology for assessing the PL of the design or performance of a control circuit.

Q. My company buys #CE marked machines and robots and uses them in automated production lines. How does the new #MachineryDirective affect us?

A. It is now very clear that your company creates an assembly of machines or "partly completed machines" and that assembly must be CE market. Particular consideration must be given understanding the risks created by the interaction of machines and to ensuring "...the safety related parts of the control system must apply in a coherent way to the whole of an assembly of machinery and/or partly completed machinery..."

A few standards organizations:

ISO- International Standard Organization 

ISO is a worldwide federation of national standards bodies. ISO has 158 national members out of the 195 countries worldwide. It has three membership categories: Member Bodies, Correspondent Members and Subscriber Members. Member Bodies are national organizations that are considered to be the most representative standards body in each country. They are the only members of ISO that can vote. Correspondent Members are countries that don’t have their own standards organization. These members are informed about ISO’s work, but do not participate in the publishing of standards. Finally, Subscriber Members are countries with small economies. They pay a reduced membership fee and can follow the development of standards. Click here to view the ISO countries.

OSHA- Occupational Safety and Health Administration

OSHA is part of the US Department of Labor. Enforcement is directed by the employer. OSHA is part of the Federal Government. Some states have opted out and have their own Occupational Safety & Health plans, which must meet or exceed the federal requirements. OSHA standards form part of the US Code of Federal Regulations. They are available free online. Many are based on earlier (obsolete) versions of ANSI standards. If you meet the current equivalent ANSI standard you will typically at least meet the intent of the OSHA regulation.

Are #robots equipped with safe motion technology more expensive then traditional robots?

Generally speaking, yes, but it is a value added cost. The features seen with safe motion allow the customers to provide a leaner, safer and more flexible manufacturing environment. This will lead to inevitable cost savings.

Q. What types of manufacturers are currently using safe motion?

A. The technology is just now starting to be seen in the market. Its pioneers are the robot manufacturers and motion (servo drives, frequency drives, etc.) providers.

Q. What challenges or hurdles still need to be addressed in #safemotion?

A. From a product perspective, the challenge becomes managing the amount of data which is induced in the real time interaction between the external (vision based) area sensors and the safe motion control systems. Your control system changes from a discrete (on/off) bitwise communication to that of a dynamic interaction /reaction between the two devices. This will require standardized communication protocols as well as control algorithms in order to make efficient use of the data.

Q. How does the #MachineryDirective apply if I build a mechanical assembly such as a conveyor belt but do not supply or fit the motor?

A. This situation is anticipated in the directive and covered by a definition:' an assembly...missing only the components to connect it to...sources of energy and motion."

Q. How are the challenges of safe motion being addressed by Pilz?

A. First, there are two sides to these types of operations:

1. The safety from the motion component side (i.e. robot, drive, etc.) verifying what motion is occurring
   
2. The external feedback for these components (i.e. what's going on in the immediate environment)
   These two components determine how the motion component should act in regard to changes in its environment. For example, as an operator approaches a robot, it should reduce speed, change its position to perform an operation away from the operator or stop to a safe stat in order to eliminate any hazard it poses to the operator.
   

With regard to Pilz products, we're designing safe motion into our PMC drives, including features such as safe stop and safe speed. We've also developed a safe area monitoring device called SafetyEYE, which monitors the immediate area in 3D, supplying control signals to the motion device when an object enters the area. This provides the feedback necessary to slow, stop or change the motion in order to adapt to a changing environment.

Q. Are there any changes to the definition of machines covered under the new MachineryDirective?

A. There are a number of refinements and additions to the definition of a machine. The core definition of a machine is now:

An assembly, fitted with or intended to be fitted with a drive system other than directly applied human or animal effort, consisting of linked parts or components, at least one of which moves, and which are joined together for a specific application.

A machine must have a "drive system" such as an electric motor, linked parts one of which moves, such as a mechanical slide and must be constructed to perform a specific application, such as molding a plastic part or welding two parts together.

Q. What types of industries would benefit most from safemotion? Example of a possible scenario where humans can work closer to robots?

A. Any industry with direct human/process interaction. Typical applications in assembly would be part loading, part inspecting/gauging, welding or preventative maintenance of the cell/application. An example of a load operation with a robot would include the following process:

1. Operator loads work piece onto table and steps away
2. Robot picks up the piece and holds it for weld, or welds it on the table
3. Robot moves away or places piece back on the table
4. Operator removes the welded piece and places a new one on the table

With safe motion, the work table could essentially be removed, allowing the operator to place the work piece directly on the robot end effector. This would, remove a large physical barrier (i.e. the table) from the work area, as well as eliminate several steps from the operation.

Q. What challenges or hurdles still need to be addressed with safe motion.

A. The standards provide the performance criteria for more sophisticated applications, but there are still many opportunities to implement the more complex applications that are now permitted. In robotics, the most challenging applications involves systems that continue to operate in the present of operators. The collaborative operating mode of maintaining a safe distance between the robotic arm and the operator is yet to be realized. Also, yet to be achieved, is the mode of operation in which the robotic arm force, torque and momentum is limited to inherently safe levels.

The advantage of safe motion, is that it allows the user a closer proximity to the actual process. With safe motion (whether it's safe speed, position or torque), if you can guarantee that the robot/drive is doing exactly what it's intended to (ie. working in a restricted space, at a restricted speed or is at stop), you can reduce and even eliminated your "safe distance" requirements. This would allow the operator to essentially work hand-in-hand with the motion component, increasing production time, reducing floor space and giving the operator a more friendly & ergonomic working environment.

Q. How do safe motion systems work? What role does advance motion control technology play?

A. Reliability theory has been applied to adjustable speed drive technology to define the reliability required for safety applications. There is an acceptance in industry for concept of integrity levels. Higher CPU power, reliability of components and a high level of diagnostics to detect dangerous faults before a failure can prevent a safety function from occurring has allowed these functions to be realized. Application of redundancy and diversity to complex control systems provides a means to predictable and acceptable failure rates.

What happens if a worker is injured as a result of safety defect on a machine?

Many factors come into consideration in answering this question. The new Machinery Directive requires member states to implement penalties that are effective, proportionate and persuasive. However, it is up to each member state to decide on the appropriate penalties. Other national laws may come into play in relation to civil or criminal prosecutions. It should be understood that the "Product Liability Directive" applies in cases where a product "does not provide the safety which a person is entitled to expect."

What is the concept of safe motion? How does it apply to robotics?

Safe motion is the capability of providing motion control functions at an integrity level high enough to reliably provide risk reduction in safe dependent applications. An integrity level is the measure of the predicted failure rate of a control function. Risk, the possibility of harm in relationship to the potential degree of severity, must be reduced to a tolerable level in a safety application. A given integrity level ensures the possibility of harm occurring is sufficiently reduced to be tolerable for a safety related function. These integrity levels and design requirements are now defined in IEC 61800.

Safe motion extends the safeguarding of hazardous motion beyond the traditional dropping of power to the motors when personnel are exposed to a hazard. With safe motion, these are some of the new safe functions available by allowing power to continue to flow to the drives and to the motors:

• Safe torque off
• Safe controlled deceleration to a stop
• Safe operational stop (safe stand still)
• Safely limiting speed or torque
• Monitoring a position or maintaining a speed 

Protective measures implemented in traditional control systems such as reduced speed and hold-to-run functions can be further enhanced through this higher integrity.

In robotics, new applications are now available to the user. The international standard ISO 10218, for robotic safeguarding, is defining new applications for safe motion.

Setting safety related axis limits and defining safety zones in three dimensional spaces is allowing easier reduction of the restricted space of a robot to provide maximum clearance while minimizing the work cell.

ISO 10218 allows for collaborative operation between the robot and the human. In this application the robot may be allowed to stay in automatic, with power available to the motors and possibly continue its motion. The robot may safely limit its speed and if necessary top in a safe standstill mode (safe operational stop) while the operator works on a part in the robots gripper. A safe operational stop is characterized by the halting of motion, but keep torque output on the motors to resisting external forces. Coupled with sophisticated presence sensing technology, all the variations of this application have not been thought of yet.

Is this the only directive impacting suppliers and users of machinery?

No. There are a number of other directives, many dating back to the 1980's, that you need to be aware of. When creating the single market, the social partners agreed that protection of the Health, safety and Welfare of workers was a key value within the community. This led to the enactment of the "Council Directive 89/391/EEC of 12 June 1989 on the introduction of measures to encourage improvements in the safety and health of workers at work."

Another important directive is "Council Directive 89/655/EEC of 30 November 1989 concerning the minimum safety and health requirements of the use of work equipment by workers at work" (and subsequent amending directives 95/63/EC and 2001/45/EC). This directive impacts employers who use machinery and sets out minimum requirements for existing machinery and requires that all new machinery should meet the requirements of all applicable directives, including the machinery directive.

Q. Did the original directive result from the creation of the single market in Europe?

A. Yes, the single market depended on the elimination of barriers to trade between member states and enshrined protection for the freedom of movement of capital, people, goods and services. The Engineering and Machine building sectors were and are important sectors of the European economy. However, prior to the first machinery directive there were no common regulaions or standards for machinery supplied on the market. The aim of the EU in introducing the Directive 89/392/EEC and it's amending Directive 98/37/EC, generally known as the "Machinery Directive", was to ensure the free movement of the products within the scope by guaranteeing a high and common level of protection in the areas of health, safety and consumer rights.