Strategic safety
Stewart Robinson of Pilz Automation Technology explains how getting the safety concept right can make a significant difference to the installed price of a machine’s safety system and its long-term cost-of-ownership.
Whether you are designing a new machine from scratch, or modifying or upgrading existing machinery, it is essential to give due consideration to the safety systems. And while the ideal will always be to consider safety at the earliest possible stage in the design of new machinery, it is a fact of life that safety systems often have to be designed to work in conjunction with specific machine functions, existing hardware or defined automation control systems. In all cases, however, the person developing the overall safety concept needs to have an in-depth knowledge of the relevant legislation, regulations and standards, as well as the appropriate safety technologies. In addition, it is important to have a sound understanding of ergonomics and the working practices of the industry in which the machine will operate.
The difference between a good safety concept and a poor one can be substantial, with serious long-term implications. A good safety concept will offer a level of safety that conforms with the relevant standards and legislation - but without being over-engineered and prohibitively expensive. On the other hand, a poor safety concept may fail to meet the necessary standards or hinder the machine operators, leading them to seek ways to overcome the safety measures. Furthermore, a poor safety concept can make machine maintenance more difficult and time-consuming, impact on availability through a high number of false trips, and can itself be difficult to diagnose and maintain.
Pilz Automation Technology has many years of experience in developing safety concepts for a wide variety of machine types used throughout a broad spectrum of industries. Furthermore, additional support can be requested from the Pilz consultants and engineers in Germany if required - or, indeed, any of the Pilz subsidiaries around the world.
Every project starts with a thorough risk assessment. Detailed engineering proposals are then presented to the customer, with mechanical, electrical and other measures combined to create a safety concept that fulfils the necessary legislative, regulatory and standards requirements, while also following industry best practice and taking account of the customer’s stated preferences.
Customers can then develop the safety system themselves or pass the safety concept to a supplier as part of the safety system’s specification. Alternatively, Pilz can provide engineering services - and an extensive range of machinery safety products - to support the customer during the machine design, build and commissioning, or Pilz can put the customer in touch with panel builders or system integrators as appropriate.
Pilz Automation Technology develops, manufactures and supplies process and automation control products for use wherever there is a requirement to ensure the safety of plant, personnel or the environment. Included in the range are: safety relays; configurable safety controllers; programmable safety systems (safety PLCs) for use with or without the SafetyBUS p safe, open industrial fieldbus network; mechanically actuated and non-contact guard switches; safety light curtains; 2D and 3D vision-based safety sensors; emergency stop switches; conventional and touchscreen operator interfaces; plus control and monitoring relays for non-safety applications.
In addition, Pilz provides safety-related services, such as training, engineering, consultancy and competence management. For 20 years Pilz has taken a leading role in educating the market with regard to safety legislation. This has been through seminars on legislation, software packages that assist with standards compliance and product selection, and publications. Pilz has produced six editions of the Guide to Machinery Safety, a Guide to Programmable Safety Systems, and publishes a free monthly email newsletter
