0 safety presentation master v1
•Download as PPT, PDF•
2 likes•1,890 views
The document discusses safety solutions from Rockwell Automation, including: - A range of safety products such as light curtains, laser scanners, safety mats, switches, and controllers to integrate safety functions. - Challenges customers may face with safety like reduced productivity and increased costs. - How Rockwell can help customers implement the right safety solutions to comply with regulations while maintaining performance. - Integrating safety directly into standard automation solutions to simplify architectures and lower costs.
Recommended
More Related Content
What's hot
What's hot (19)
Viewers also liked
Similar to 0 safety presentation master v1
Similar to 0 safety presentation master v1 (20)
More from confidencial
More from confidencial (20)
Recently uploaded
Recently uploaded (20)
0 safety presentation master v1
- 1. Safety Solutions HOME Copyright © 2009 Rockwell Automation, Inc. All rights reserved.
- 2. Safety. Is it a challenge for you? It is common knowledge that legislation requires safe operating environments within manufacturing. And working to standards is a good method to show you comply. But are you facing additional challenges you didn’t expect… Challenges • Has making your machines / process safer, raised issues – Does it effect the performance of your equipment • Stopping when it shouldn’t stop? Nuisance tripping? – Is it costing you too much? • Are you implementing too much safety? • Are you implementing a safety solution that causes issues • Managing additional safety suppliers costs your company – Is safety limiting your ability to: • Run your machine productively and efficiently • Carry out maintenance tasks quickly and easily • Get your machines to your customer quickly • Have incidents increased in your plant? – Are your safety measures applied correctly? – Is it costing you in personnel accident payments and disability payments HOME
- 3. Working with Rockwell Automation • An automation supplier that understands automation and safety… not just safety. – Helping you get performance you need… safely – Cost – helping you get the most from your investment – Legislation requirements – helping you achieve conformance • A full range of services and solutions for safer automation – A comprehensive product portfolio (input / logic / actuation) – Safety services (assessments, validation, training etc) • Integrating safety functions into standard automation solutions – – – – Drives, PLC, I/Os, Motion, networks, programming software… Simplifying your architecture Lowering cost Increasing performance HOME
- 4. HOME
- 5. Integrated safety solutions FACTORYTALK™ Tell me more about… Rockwell Automation NETLINX™ NETWORKS Integrated Architecture Integrated safety solutions APPLICATION KNOWLEDGE Safety challenges and solutions HMI INDUSTRY SOLUTIONS INTEGRATED SAFETY SOLUTIONS Select from menu below: 1. Fault identification – visual ID 2. Fault identification – System diagnostics SAFETY INPUTS SAFETY LOGIC CONTROLLERS SAFETY ACTUATORS 3. Safe zone control – increased productivity CONNECTION SYSTEMS 4. Safe zone control - maintenance 5. Simplified Design – Premier Integration 6. Optimizing lock out and tag out access 7. Simplifying line expansion 8. Remote access troubleshooting 9. Cross beam muting – increase productivity 10. Integrated Safety – Safe torque off SAFETY WWW LEGISLATION & STANDARDS GUIDANCE SAFETY SERVICES 11. Integrated safety - Reduce system complexity 12. Safe limited speed for maintenance 13. Zero speed access – reduced downtime 14. Safe acceleration and deceleration HOME
- 6. Products – Safety input devices Presence sensing safety devices • • Detection of a person or moving object Passive safety interlocking option - no physical action required between the devices and the operator/object Safety interlock switches • • Physical Interlocking of guard doors or systems Opening the guard door activated the interlocks Non-contact or physical interlocking versions are available Versions to lock guard door closed available Key exchange systems • Devices include: – – – – Safety light curtains Safety laser scanners Pressure sensitive mats Pressure sensitive edging • • – – – – – – • • Devices used in the event of an emergency to stop a hazard Versions with push-button or rope (cable) pull actuation Operator interface • Devices include: • • • Emergency stop & trip devices Devices include: – – Emergency stop buttons Cable pull safety switches • • Devices used to safety interact with applications Physical actuation of capacitive actuation Devices include: – – Enabling grip switches Two hand controls Tongue operated interlocks Hinge operated interlocks Guard locking interlocks Non-contact interlocks Safety Limit Switches Trapped key systems HOME
- 7. Products – Safety logic controllers Monitoring safety relays • • • • Dual channel monitoring of the safety systems Comprehensive range for your application Single function, modular of configurable versions Programmable safety controllers • Packaged safety controller (SIL3) • Programmable using RSNetWorx software • CIP safety over DeviceNet and optional EtherNet/IP version for diagnostic comms Devices include: • Communicates and controls – MSR100 - Single function safety relays safety I/O – – MSR200 – Modular safety relay system MSR300 – Configurable safety relay system • Devices include: – – Integrated safety controllers • • • • • GuardLogix integrated safety controller (SIL3) for ControlLogix Standard and safety control in one platform CIP safety over EtherNet/IP or DeviceNet Communicates and controls safety I/O Devices include: – Safety I/O devices • • • • Safety rated I/Os EtherNet/IP or DeviceNet connectivity Use with programmable and integrated safety controllers Devices include: – – – CompactBlock GuardI/O ArmorBlock GuardI/O POINT GuardI/O GuardLogix PAC SmartGuard 600 GuardPLC HOME
- 8. Products – Safety actuators Safety contactors • • Mechanically linked, positively guided contacts Feedback circuit for safety integrity Range of power ratings • Devices include: • – – – 100S Safety Contactors 700S Safety Contactors 109S Safety Contactors PowerFlex AC drives • • PowerFlex AC drives with optional integrated safety functions Advanced safety functions in PowerFlex 750 series AC drives May replace the need for safety contactors Remove torque without powering down machine Restart machines faster • Kinetix integrated motion • Devices include: • • • – – – – • Kinetix 6000 with optional integrated safety functions Safe Torque Off and advanced safety Remove torque without powering down machine Restart machines faster • Devices include: • • – – Kinetix 6000 Kinetix 7000 PowerFlex 40P PowerFlex 70 PowerFlex 700S PowerFlex 755 HOME
- 9. Products – Connection systems / networks ‘Quick connect’ connection systems • • • Quick connect / disconnection systems Reduces installation time and simplifies troubleshooting Devices include: – – – CIP Safety over DeviceNet • • • • Cordsets and patchchords T-ports Distribution boxes • Open device level network Standard and safety communication across DeviceNet media Uses the proven Common Industrial Protocol (CIP) Provides, control, configure and data collection capabilities Devices include: – – – Physical media Sensors, controllers and actuators Software CIP Safety over EtherNet/IP • • • • Open device level network Standard and safety communication across EtherNet/IP media Uses the proven Common Industrial Protocol (CIP) Devices include: – – – Physical media Sensors, controllers and actuators Software HOME
- 10. GuardShield: Safety light curtains • Allen-Bradley Guardmaster safety light curtains offer optimal safety while allowing for greater productivity and ergonomics on the work floor. – – – – – – – – – – Safety category 2 or 4 PNP Outputs (2 N.O. Safety + 1 N.O. Aux.) 14 mm or 30 mm objects sensitivity (POC only) Up to 18m sensing range Fixed blanking — teachable (POC only) Floating blanking — one or two beams (POC only) Beam coding External device monitoring (EDM) Start/restart interlock TUV approved • Products include: – – – – Point of Operation Control light curtains (POC) Perimeter Access Control light curtains (PAC) Area Access Control (AAC) Micro-sized light curtains for when space is a premium HOME
- 11. SafeZone: Safety laser scanners • The SafeZone™ Multizone safety laser scanner provides flexible area guarding within hazardous cells. – – – – – – – – – Vertical or horizontal mounting in stationary or mobile applications Auto configured safety field using ambient contour Angular scanning range 190°, Safety field range 5 m Application resolutions of 30mm, 40mm, 50mm, 70mm, or 150 mm Configurable samplings: 2-16 samplings before outputs switch off Configurable restart delay: 2 to 60 sec 7-segment diagnostic display Application diagnostic output CE and cULus marked, meets Category 3 per EN954, Type 3 IEC61496 and SIL2 per IEC61508 HOME
- 12. MatGuard: Pressure sensitive safety mat system • Highest quality safety mat available today. This robust family of products withstands the force of a forklift driving over it, yet is sensitive enough to be triggered by the footstep of a 30kg person. – – – – – – – Category 3 according to EN954-1 (ISO 13849-1) Third party certification to EN 1760-1 Overall sensitivity including uniting strip Rugged construction withstands the pressure of 4500psi IP 67 vinyl construction resistant to most oils 5-year warranty Mat manager monitors the status of up to 8 mats individually HOME
- 13. Safedge: Pressure sensitive edge system • • • • • Pressure sensitive system can be applied along or around applications Ideal for use in potential trapping or pinch points Utilises durable rubber compound (conductive and non conductive) Selection of cushion sizes: 5mm (0.2 in), 19mm (0.75 in) and 41mm (1.6 in) Order parts and configure yourself or specify factory configured solution for you application • Up to 50m lengths with min bend radius of 500mm (19.6 in) • Fully active corners • Utilizes safety controller HOME
- 14. Tongue operated interlock switches • Ideal for interlocking of sliding, hinged and lift-off guard doors • These devices require a physical actuator key to be inserted or removed from the switch for operation • Positive actuation via direct opening contacts • Versions with metal and plastic housings for flexibility and robustness • Small 25mm width versions for use in small spaces • A range of fixed, semi-flexible and fully flexible actuators allow application flexibility • Versions with actuator holding force ≤ 40 N (9 lbs) • Conduit: Metric, ½ inch NPT and quick connect versions available • Note: These devices do not lock the guard HOME
- 15. Hinge operated interlock switches • • • • • • • • Ideal for interlocking of hinged guard doors Designed to fit onto the hinge or be the hinge-pin Positive actuation via direct opening contacts Small 25mm width versions for use in small spaces Versions with 4 possible shaft positions – easy to install Ideal where door misalignment or contaminants may cause issues Versions with metal and plastic housings for flexibility and robustness Conduit: Metric, ½ inch NPT and quick connect versions available • Note: These devices do not lock the guard HOME
- 16. Guard locking interlock switches • Ideal for interlocking of sliding, hinged and lift-off guard doors • Guard locking interlocks help keep guard door locked closed until a safe machine condition exists • These devices require a physical actuator key to be inserted or removed from the switch for operation • Positive actuation via direct opening contacts • Power to release and power to lock versions • Versions with actuator holding force ≤ 5000 N (1124 lbs) • Versions with metal and plastic housings for flexibility and robustness • A range of fixed, semi-flexible and fully flexible actuators allow application flexibility • Conduit: Metric, ½ inch NPT and quick connect versions available • Rotatable head: 4 possible actuator key entry slots (440G-MT and TLS-GD2) HOME
- 17. Non-contact interlock switches • Ideal for interlocking of sliding, hinged and lift-off guard doors • Requires no physical contact between the switch and actuator to achieve operation • Small physical sizes, ideal where space is at a premium • Suitable for wash down thus ideal for hygiene sensitive applications • Versions available with 25 mm assured sensing distances • Versions with and without control units • SensaGuard family offer: – – – – – RFID coding for security integrity Inductive technology for sensing High tolerance to misalignment Achieves Cat. 4 / SIL3 ratings even when wired in series Visual diagnostics for ease of troubleshooting • Note: These devices do not lock the guard HOME
- 18. Safety limit switches • Comprehensive range of safety limit switches • These devices require physical actuation of the head mounted actuator for operation • Positive actuation via direct opening contacts • Versions with metal and plastic housings for flexibility and robustness • Snap-acting of slow-break/make contacts • A range of actuator types for application flexibility – – – – Roller plunger Dome plunger Lever operated Offset hinge lever • Conduit: Metric, ½ inch NPT, pre-wired and quick connect versions available HOME
- 19. Prosafe trapped key systems Based upon the premise that no one key can be in two places at once, key interlock systems can be configured to provide a predetermined sequence of events takes place or that hazards have been reduced before operators can become exposed to them • Individually coded keys for high security • All stainless steel interlocking and coded parts • Replaceable code barrel assembly for key sequence change-over or part replacement • The range includes: – Power isolators (electrical, pneumatic etc) – Key exchange units – Interlocks (single and dual key) • Bolt interlocks, access/chain interlocks, tongue interlocks, miniature valve interlocks HOME
- 20. Emergency stop buttons • Variety of operator sizes and contact configurations • Patented Self-Monitoring Contact Blocks (SMCB) monitors if the contact block is correctly fixed to the mushroom actuator – IP2X finger-safe protection – Terminals identified with IEC-style markings – If the SMCB is separated from the E-stop operator for any reason, the controller circuit will automatically open • Twist to release, key release or pull to release options • Versions with LED mounted indication • Self configurable contact block HOME
- 21. Cable (rope) pull safety switches • The Lifeline family of cable-actuated emergency stop switches is ideal for installation along or around awkward machinery such as conveyors, and provides a continuous length of emergency stop access via the cable (rope) – – – – – Unique cable grip system System can be installed and commissioned quickly Up to 300 mm of cable tension adjustment IP67 stainless steel versions available Cable span up to 125 m for standard models and 75 m for stainless steel models – Switch mounted mushroom Emergency stop button on Lifeline 4 versions – Visual rope tension indicator HOME
- 22. Enabling grip switches • Manually operated device used in conjunction with a start command • Safety function of the enabling grip switch has two parts – When continually actuated, machine can operate – When not actuated, switch initiates a stop command • 3 position switch with middle position as actuated (safety contacts closed, machine run) • Gripping or releasing the enabling grip switch either way of the middle position will generate a machine stop command • Versions available with: – Machine jog / restart button – E-Stop mounted mushroom button • Ideal for maintenance applications where limited power has to be maintained HOME
- 23. Two-hand control devices • Ideal for machine control systems requiring two hand operation • Internationally rated ergonomic touch buttons • Capacitive sensing - Zero force to operate • Diagnostic LED’s for status indication and troubleshooting • Pre-wired or quick connection options • Robust design for use in demanding environments HOME
- 24. Minotaur MSR100: Single function safety relays • For Applications up to Category 4 EN954-1, PLe EN ISO 13849-1 and SILCL 3 to EN IEC 62061 • Preferred units – – – – – – – MSR117/127/131: Basic function units. MSR142: multiple outputs. MSR144: expandable module. MSR138: delayed outputs module - control stop to EN60204-1 MSR125H: 2-hand control module MSR30/33/35/38: Solid state relays MSR57P: Speed Monitoring Relay • Safe Torque Off • Zero Speed Monitoring • Safe Limited Speed • Safe Stop to Cat 0, 1 or 2 • Safe Maximum • Safe Acceleration and Deceleration • Door monitoring and control • Enabling grip switch control HOME
- 25. Minotaur MSR200: Modular safety relay system • Modular dual processor system – Modular – Expandable micro-processor system – Flexible – Guards, E-stops, safety mats, light curtains • Safety Integrity – Individual input channels, 2 input channels per module • Configuration – Inputs: 10 modules (22 inputs) – Outputs: 2 modules (instant and delayed versions) – Diagnostic display and communications module • Economic – Reduced wiring cost – processors control logic. – Reduced inventory cost • Ease of Installation – Wiring, interconnections, input and output expansion • Compact – Smaller panel space required HOME
- 26. Minotaur MSR300: Configurable safety relay system • Modular MSR300 system – Logic configuration with multiple inputs – Control up to 3 independent output zones. • Muting functionality for controlled access – Ideal for parts loading in robotic cells • Output modules for three groups (zone control) – Each input module can be configured to switch one or more output groups • Cat.4 EN 954-1, SIL3 IEC 61508 approvals • Configuration – Inputs: 20 per base module – 3 independent output zones – DeviceNet module for diagnostic communication HOME
- 27. SmartGuard 600 safety controller The SmartGuard 600 safety controller is a programmable safety controller designed for safety applications that require some complex logic, allowing for more advanced safety functionality • Ideally suited for applications: – Where a safety relay isn’t enough and a safety PLC is too much – Using: E-Stop, Safety Gate, Light Curtains, Two-hand Control, Multi-zone Control • 16 inputs, 8 outputs, 4 pulse test sources • Connectivity / Communications – CIP Standard and Safety over DeviceNet – CIP Standard over EtherNet/IP (for diagnostics only) – USB port for configuration and programming • Programmed via RSNetWorx for DeviceNet • Certified to Cat. 4, SIL3, PLe, UL NRGF, UL Class I Div 2 HOME
- 28. GuardPLC safety controllers and distributed I/O Packaged safety controllers • GuardPLC 1600 – 20 digital inputs, 8 digital outputs • GuardPLC 1800 – 24 digital inputs, 8 digital outputs, 8 analog inputs and 2 high speed counters • Integrated 4-port Ethernet switch • EtherNet/IP connection to standard controller • Modbus or Profibus communication options – Allows for direct connection to PanelView and others • GuardPLC distributed I/O blocks – A comprehensive range available – Digital and analog inputs and outputs • Configured using RSLogix Guard PLUS software HOME
- 29. GuardLogix - ControlLogix safety integration • Standard control and safety control in one controller GuardLogix – One common chassis – Standard and safety control on common networks – Single programming environment with RSLogix 5000 • ControlLogix Integrated Safety – – – – – – Dual Processor Solution (1oo2 Architecture) SIL 3 Certification per IEC 61508 PLe according to EN ISO 13849 EN 954-1 Category 4 Certified Safety Application Instructions CIP Safety over DeviceNet and EtherNet/IP HOME
- 30. CompactBlock Guard I/O • Compact, space saving safety I/O blocks • Communication via CIP Safety over DeviceNet or EtherNet/IP • Easy migration between DeviceNet and EtherNet versions – Common I/O circuits – Common interface and Logix profiles – Common set of terminal blocks • IP20 rated package for use in cabinet • Programmed via RSLogix 5000 v16 or later HOME
- 31. ArmorBlock Guard I/O • Same functionality as CompactBlock Guard I/O – Control Flash compatible – Shock rated to 30g, tested to 50g – Improved temperature range to -20°C to 60°C • IP67 rated package for use on machine • Simplified Installation: a single M12 cable connects to dual-channel devices on inputs and outputs, using quick disconnects • Compatible with quick disconnect standard sensors and safety devices • Same input and output M12 pins as standard ArmorBlock • Can connect dual or single channel devices • 180mm x 70mm housing • Separate Input and Output Power via mini connector HOME
- 32. POINT Guard I/O • Integrated safety and standard control into 1734 POINT I/O product line • POINT I/O provides high density and granularity to optimize your design – POINT standard (grey) I/O available in 2,4, and 8 point module densities – POINT Guard I/O (red) safety modules available • 1734-IB8S - 8 Point Safety Sink Input • 1734-OB8S - 8 Point Safety Source Output • • • • • For use with GuardLogix® and SmartGuard™600 Logix 5000 used to configure both standard and safety functions over EtherNet/IP Compact design: combining safety + standard POINT I/O saves panel space Certified to Category 4, SIL 3, PLe Compatible with other POINT I/O products: – – – – 1734-AENT and 1734-AENTR 1734-PDN and 1734D 1734 terminal blocks (all except 1734–TB3) Can be used with other POINT I/O modules, including: • Digital, analog, specialty, and Encompass products • Electronic over current protection of all outputs HOME
- 33. Safety contactors • Safety Contactors provide either mechanically linked or mirror contacts, which are required in feedback circuits for modern safety applications • Mechanically linked (positively guided) contacts are linked together thereby preventing the re-closing of the N.C. contacts if a N.O. contact has welded • This helps to protect personnel from unintended machine starts and loss of the safety function • Suitable for use in safety categories B…4 • Protective cover to prevent manual operation HOME
- 34. PowerFlex AC drives with optional integrated safety • Safety functionality is available as an optional integrated feature • Power can be maintained to the drive after a demand on the safety function – The DC bus is not discharged – Reduces wear on drive increasing life – Quicker restart times for higher productivity • Simplified circuit with less wiring • Input or output contactors may not be required • Standard Safe Torque Off available in: – PowerFlex 40P, 70, 700S, 755 • Advances safety functions available in: – PowerFlex 755 and subsequent 750 series • Advances safety offers: – – – – Safe Torque Off Zero Speed Monitoring Safe Limited Speed Safe Stop to Cat 0, 1 or 2 – – – – Safe Maximum Safe Acceleration and Deceleration Door monitoring and control Enabling grip switch control HOME
- 35. Kinetix integrated motion with optional integrated safety • Safety functionality is available as an optional integrated feature • Power can be maintained to the drive after a demand on the safety function – The DC bus is not discharged – Reduces wear on drive increasing life – Quicker restart times for higher productivity • Simplified circuit with less wiring • Input or output contactors may not be required • Standard Safe Torque Off available in: – Kinetix 6000 and 7000 • Advances safety functions available in next release of: – Kinetix 6000 • Advances safety offers: – – – – Safe Torque Off Zero Speed Monitoring Safe Limited Speed Safe Stop to Cat 0, 1 or 2 – – – – Safe Maximum Safe Acceleration and Deceleration Door monitoring and control Enabling grip switch control HOME
- 36. Connection systems • Comprehensive range of cables, cordsets, patchcords, Y-cables, distribution boxes and receptacles • Connect your devices quickly and seamlessly • Simplify system complexity • Reduce wiring channels • Speed up machine build time • Increased diagnostics to assist troubleshooting • Replace devices quickly and easily • Large range of safety devices supported HOME
- 37. CIP Safety over DeviceNet • DeviceNet is a simple, open networking solution that reduces the cost and time required to wire and install industrial automation devices, while providing interchangeability of like components. • Reduces wiring and installation cost – Labor and hardware expense • Reduces start-up time – Minimizes wiring errors – Makes it easier to “stage” sub-systems – Allocate resources to next job quickly • Significantly reduce downtime and total cost of ownership with the aid of diagnostics, Auto Device Replacement, and other time- and cost-saving features • Run standard and safety applications on the same wire • It’s an open network – Specification maintained by Open DeviceNet Vendor Association (ODVA) • Control, configure, and collect data on a single network • Pre- and post-sales tools available for system planning and configuration HOME
- 38. CIP Safety over EtherNet/IP • EtherNet/IP based on the standard Ethernet architecture, is an industrial open networking solution that reduces the cost and time required to wire and install industrial automation devices, while providing interchangeability of like components • Reduces wiring and installation cost – Labor and hardware expense • Reduces start-up time – Minimizes wiring errors – Makes it easier to “stage” sub-systems – Allocate resources to next job quickly • Significantly reduce downtime and total cost of ownership with the aid of diagnostics, Auto Device Replacement, and other time- and cost-saving features • Run standard and safety applications on the same wire • It’s an open network – Specification maintained by Open DeviceNet Vendor Association (ODVA) • Control, configure, and collect data on a single network • Pre- and post-sales tools available for system planning and configuration HOME
- 39. Conventional solution – Fault identification HOME
- 40. Challenges and costs associated with this scenario ? Conventional safety solution 1. 2. 3. 4. 5. Production stops. Why? Manually locate the relevant guard or zone Establish the reason for the trip - Is it a Mechanical or Electrical fault Was it avoidable? Confirm / repair the problem, reset and start process (Minutes……….Hours……..Days ??) Unplanned downtime due to guard door misalignment Maintenance activity is reactive rather than proactive No diagnostic capability Meeting production targets are not under control !! HOME
- 42. Benefits to your business Contemporary Safety Solution 1. Production did not stop due to warning and diagnostics functions provided by simple visual identification 2. Production loss ZERO !! Unplanned downtime reduced to a minimum Production targets can be met consistently Where required pro-active maintenance can be scheduled to avoid further issues and downtime Fact based decisions can be made due to Diagnostic data available HOME
- 43. Conventional solution – Fault identification HOME
- 44. Challenges and costs associated with this scenario ? Conventional safety solution 1. 2. 3. 4. 5. Production stops. Why? Manually locate the relevant guard or zone Establish the reason for the trip - Is it a Mechanical or Electrical fault Was it avoidable? Confirm / repair the problem, reset and start process (Minutes……….Hours……..Days ??) Unplanned downtime Maintenance activity is reactive rather than proactive No diagnostic capability Meeting production targets are not under control !! HOME
- 46. Benefits to your business Contemporary Safety Solution 1. Production did not stop due to warning and diagnostics functions provided through Integrated Architecture 2. Production loss ZERO !! Unplanned downtime reduced to a minimum Production targets can be met consistently Streamlined architecture reduces system complexity allowing simpler maintenance and flexibility to change Where required pro-active maintenance can be scheduled to avoid further issues and downtime Fact based decisions can be made due to Diagnostic data available HOME
- 47. Conventional solution – Zone control for productivity HOME
- 48. Challenges and costs associated with this scenario ? Conventional safety solution? 1. 2. 3. Production has to stop to allow loading of parts Robot would need to be homed if light curtain is tripped without controlled machine stop One loading zone allows limited parts to be loaded Limited productivity due to repeated machine stops for parts loading Unnecessary downtime Safety was applied without looking at the ‘Function’ of the machine HOME
- 50. Benefits to your business Contemporary Safety Solution 1. Production does not stop when parts are being loaded 2. Zone control technique used to increased productivity 3. The ‘Function’ of the machine used in applying a safety solution Downtime due to restocking is reduced to a minimum Production targets can be met consistently Machine and operator interaction streamlined Safety is designed into the machine and operator interfaces Start-up routines minimised HOME
- 51. Conventional solution – Zone control for maintenance HOME
- 52. Challenges and costs associated with this scenario ? Conventional safety solution? 1. 2. 3. 4. 5. All production cells stop for individual robot maintenance A demand on the safety function will stop the whole cell Physical guarding required to protect the cell No detection of personnel inside the cell Power isolation required for access Multi-robot downtime is costly!! Productivity impacted No partial power for robot jogging / teaching HOME
- 54. Benefits to your business Contemporary Safety Solution 1. Whole production cell did not stop for individual robot maintenance 2. Safe limited speed and zone control techniques used 3. The ‘Maintenance Mode Function’ of the machine is identified and considered when applying the safety solution 4. Space saving achieved as no physical guarding required Planned/unplanned downtime for maintenance effects only specific cell Production targets can be met consistently Integrated safety used to achieve productivity and flexibility Intelligent zone control used to maximise uptime and availability Minimal physical guarding required allowing personnel and machine flexibility and safety HOME
- 55. Conventional solution – Programming and startup HOME
- 56. Challenges and costs associated with this scenario ? Conventional safety solution? 1. 2. 3. 4. Requires multiple software tools to configure the PLC, drive, I/O, motion and safety functions Remapping of defined data for each software tool: e.g., logic/descriptive tag names, data types, etc. Program configurations stored in separate files Potential errors in programming Time consuming with higher potential for errors Programming knowledge of multiple environments Operator / maintenance personnel have to be trained in multiple environments HOME
- 58. Benefits to your business Contemporary Safety Solution 1. One programming environment for safety, drive, I/O, motion and PLC 2. Auto generation of descriptive tag names/data for control and visualisation 3. Program configuration stored in one location Potential programming errors reduced to a minimum Simple to access and edit information Diagnostic, fault, alarm and event management are integral to RSLogix 5000 programming environment Reduce development time and complexity HOME
- 59. Conventional solution – Lock out and Tag out HOME
- 60. Challenges and costs associated with this scenario ? Conventional safety solution? 1. 2. 3. 4. Multiple energy sources in different locations have to be locked out If padlocks used there maybe multiple keys which could reduce lockout system integrity Potential not to lockout all energy sources No enforced sequence of events has to take place to gain access to potentially hazardous area Can be time consuming to isolate all power sources!! Lockout could be removed if multiple maintenance / personnel working which could cause a potentially hazardous risk!! Bypassing safety lockout routine can be done HOME
- 62. Benefits to your business Contemporary Safety Solution 1. Utilization of a Prosafe trapped key system enforces a sequence of events to take place before access is allowed to guarded area 2. One location to isolate all power sources!! 3. Keys can be used to ensure no restart is possible – operator / maintenance person can keep the key with him/her Enforces a standardized sequence for safety integrity Reduces time to lockout all power sources Reduces complexity and potential for bypassing Individually coded keys increase safety integrity Trapped key systems can be configured to achieve the correct ‘Functional Access’ to an application HOME
- 63. Conventional solution – Expanding your production HOME
- 64. Challenges and costs associated with this scenario ? Conventional safety solution? 1. 2. 3. Production expansion requires individual programming Multiple programming software / integrators required System complexity increases with expansion Time consuming and inflexible!! Can lead to a very costly and complex production facility!! Software revision management can be difficult and costly HOME
- 66. Benefits to your business Contemporary Safety Solution 1. Single programming environment allows for flexibility 2. Application code reuse, simplified along with revision management 3. Common networks such as EtherNet/IP or DeviceNet allow safety and automation control on one network, reducing system complexity 4. Integrating safety control into automation devices to achieve flexibility through standardised solutions Flexible automation solution with integrated safety can be easily replicated quickly and efficiently Single programming environment for ease of use in factory expansion when adapting to changing market conditions HOME
- 67. Conventional solution – Remote troubleshooting HOME
- 68. Challenges and costs associated with this scenario ? Conventional safety solution? 1. 2. 3. Web access is limited to the overall application No access to devices such as drives, safety devices, motion controllers (unless extensive code is developed in the PLC) Site visit may be required to change or troubleshoot applications Time consuming and expensive to troubleshoot Downtime while maintenance contractor arrives from another location Maintenance person does not know what has happened before arriving so can not predict required actions or hardware needed HOME
- 70. Benefits to your business Contemporary Safety Solution 1. Diagnostic information accessible down to device level 2. Remote high level support for local maintenance personnel 3. Simple issues solved quickly without need for installation visit 4. Less on-site personnel required allowing for flexible deployment of resources across multiple sites Reduced downtime and simplified troubleshooting Required actions identified remotely allowing maintenance personnel to prepare in advance of installation visit No extensive code required in PLC HOME
- 71. Conventional solution – Cross beam muting HOME
- 72. Challenges and costs associated with this scenario ? Conventional safety solution? 1. 2. 3. 4. 5. Manual operator interaction required Potential of operator to access guarded area to keep production moving Productivity limited to operator efficiency at different times of day Operator error can result in production waste Production limited to access time to filling station Can be costly to have personnel working at multiple stations Production is reliant on operator productivity and competency Physical labour can result in operator injuries with associated costs The safety function of the interlocked guard door makes the application safer but limits productivity HOME
- 74. Benefits to your business Contemporary Safety Solution 1. Light curtain with cross beam muting function used to increase access speed to filling station 2. No manual interaction required 3. Automated loading and unloading helps increase productivity 4. Personnel can not access guarded area without tripping the light curtain Increased productivity Increased integrity of safety system Reduced potential of injury and associated costs The safety solution allows an increase in productivity by adopting a ‘Functional Safety’ approach to the application HOME
- 75. Conventional solution – Reduce start-up cycle time HOME
- 76. Challenges and costs associated with this scenario ? Conventional safety solution? 1. 2. Demand on the safety function initiates stop and removes power to drive Start-up cycle time maybe considerable Cycling power to the drive reduces operational lifetime of the drive Loss of production efficiency due to recurring start-up times Complex start-up routines may have to be followed Possible loss of communications HOME
- 78. Benefits to your business Contemporary Safety Solution 1. Demand on the safety function initiates a stop. The drive remains powered but in a Safe Torque Off state with motor unable to start 2. No start-up routine needed. Process can begin immediately Drive operational lifetime maintained Minimum loss of production Less confusion and stress for operator No start-up routine needed Communications active throughout safety initiated routine HOME
- 79. Conventional solution – Reduce system complexity HOME
- 80. Challenges and costs associated with this scenario ? Conventional safety solution? 1. 2. 3. 4. All control functions located in one cabinet Automation control and safety control are independent Utilisation of traditional connection solutions Cabinets built for specific control purpose Large control cabinet requiring premium space Multiple wiring tracks increase fault possibilities and application complexity Maintenance and troubleshooting can be difficult Lengthy installation, commissioning and testing HOME
- 82. Benefits to your business Contemporary Safety Solution 1. Integration of automation control and safety control allows for smaller cabinet footprint 2. Distribution of control functions and devices around the machine 3. Utilisation of quick connection methods and standard networks such as EtherNet/IP and DeviceNet carry control and safety data 4. Local control of functions on the machine Reduces installation time and simplifies complexity Simplifies troubleshooting and maintenance Reduces required control cabinet size and associated space costs Re-useable solutions and flexibility of system configuration HOME
- 83. Conventional solution – Safe speed for maintenance HOME
- 84. Challenges and costs associated with this scenario ? Conventional safety solution? 1. 2. 3. 4. Total power removal required to carry out maintenance / cleaning Access only allowed into guarded zone if machine at stand-still Operator has to leave the guarded area, close guard door and power up to partially rotate the application to carry out maintenance / cleaning The safety system is effective but is not designed to assist in ‘Maintenance Function’ Can be time consuming to carry out basic maintenance procedure Potential of maintenance personnel to bypass safety system to achieve quicker maintenance procedure Functional Safety assessment did not cover maintenance procedure HOME
- 86. Benefits to your business Contemporary Safety Solution 1. ‘Functional Maintenance’ procedure considered in deployment of an integrated safety solution to help, not hinder maintenance tasks 2. Partial power-up under monitored ‘Safe Limited Speed with Safe Direction’ allows personnel the flexibility to efficiently carry out maintenance procedures 3. Deployment of ‘Safe-speed technology’ either through dedicated MSR57P Speed Monitoring Relay or optional integrated in PowerFlex 750 series AC drive Maintenance procedures carried out efficiently Machine downtime kept to a minimum Desire to bypass safety system no longer necessary Safety solution helps increase flexibility HOME
- 87. Conventional solution – Zero speed access HOME
- 88. Challenges and costs associated with this scenario ? Conventional safety solution? 1. 2. 3. 4. Rotating hazardous motion not monitored for stand-still Access to guarded area only allowed after a pre-determined time even if the hazard no longer exists Delay in access time could be considerable Does not utilise ‘Functional Safety’ assessment to aid operator and machine interaction Can impact productivity as downtime can be considerable Does not benefit from frequent access requirements Can frustrate operator causing attempt to bypass safety functions HOME
- 90. Benefits to your business Contemporary Safety Solution 1. Instant access to guarded area allowed as soon as hazardous motion has stopped 2. The ‘Function’ of the machine considered when applying safety 3. Deployment of ‘Safe-speed technology’ either through dedicated MSR57P Speed Monitoring Relay or optional integrated in PowerFlex 750 series AC drive Reduces machine downtime Allows quick operator and machine interaction safely Adopts Functional Safety standards to allow flexibility Integrated safety and automation technologies reduce system complexity HOME
- 91. Conventional solution – Safe acceleration/deceleration HOME
- 92. Challenges and costs associated with this scenario ? Conventional safety solution? 1. 2. 3. 4. Acceleration and deceleration controlled and monitored by PLC Safety solution will shutdown application if fault detected No safe acceleration or deceleration options Applications may start or stop too quickly Can cause application usability issues Safe shutdown is power off and could cause potential swinging Riding comfort is uncomfortable on embarking and disembarking Application not under controlled condition HOME
- 94. Benefits to your business Contemporary Safety Solution 1. Safety monitoring of applications acceleration and deceleration 2. Helps protect against runaway condition or deceleration excess 3. Deployment of ‘Safe-speed technology’ either through dedicated MSR57P Speed Monitoring Relay or optional integrated in PowerFlex 750 series AC drive Protects assets from damage Can be retrofitted to existing applications HOME
Editor's Notes
- Overview of new controllers and top features.
- In this scenario you can see a machine with multiple interlocked guard doors. All the interlocks are connected in series back to the controller. With no diagnostic information available, over a number of months you may find that faults develop. In this example, a interlocked guard door becomes misaligned due to machine vibration thus causing an unscheduled machine stoppage. The operator would not easily be able to establish the reason for the machine stopping and would have to contact the maintenance engineer. The maintenance engineer will then need to perform diagnostic assessment on the whole application using valuable maintenance time and causing loss of production.
- In this scenario you can see a machine with multiple guard doors interlocked with SensaGuard non-contact safety switches. The interlocks have a switch mounted LED for status indication and are connected in series back to the controller. As the guard door becomes slightly misaligned, the interlocks LED will blink orange, visually notifying the operator that there is a issue. This does not stop the machine. The operator can then inform maintenance and maintenance can be performed at the next scheduled downtime of the machine thus eliminating unscheduled downtime and associated production losses.
- In this scenario we have multiple manufacturing lines with multiple guard doors, all connected back to a central controller. Over a period of time issues may arise such as vibration causing an interlocked guard door to opening slightly thus stopping production. The control system will notify the operator that the line has stopped but there will be no identification of the position or nature of the individual fault. Maintenance personnel will need to be called to troubleshoot with an aim of getting production back online. This could be time consuming resulting in lost production costs.
- In this senario we have multiple manufacturing lines with multiple guard doors. Utilising Rockwell Automations Integrated Architecture with safety and automation control seamlessly integrated, full status information is available. Here we have utilised GuardLogix as the controller with Safety I/O blocks dispersed throughout the application. Connecting all the safety devices through the safety I/O allows system status down to the individual guard door or e-stop. Therefore if an e-stop or an interlock switch is operated, that individual safety signal will be sent via CIP Safety over EtherNet/IP or DeviceNet, back to the controller. The operator receives notification that there is a fault, and will know where the fault is located so that he can either deal with it if it is not a major issue as shown here, or contact maintenance personnel which ultimately means that downtime is minimised.
- In this scenario we have a robot cell, guarded by physical barriers and light curtain system inside for personnel detection. A light curtain is used across a loading section to reduce loading issues. The operator needs to replenish parts for the robot to continue production. Loading of these parts required the operator to stop the robot while loading and unloading occurs. This lengthy process impacts productivity and manufacturing flexibility.
- In this senario, the functional operation of loading parts has been combined with zone controlled safety. You can see the robot is now working from two zones, left and right. When the operator needs to replenish part, he can set one loading section to ‘load’, thus muting the light curtain to allow loading but without stopping production. In this state the robot will be restricted to only work in the other zone. Once parts loading has been completed the zone will be un-muted and the robot can resume production utilising parts from both sides. This helps increase productivity by reducing robot and application downtime.
- In this scenario we have a physically guarded cell which is interlocked via a Guardlocking switch on the access door. For an operator to gain access into the cell he has to lock off power to the application, stopping all 5 robots. When power is removed and isolated via a key, the operator can then put that key into his pocket and gain access through the now unlocked guard door. Maintenance or repair to robot 3 can be carried out safely but this process impacts productivity and can be costly if prolonged maintenance is needed.
- In this senario there is no physical guarding around the robots. Instead the application is safeguarded by SafeZone safety laser scanners. One laser is used per robot, which allows the robots to be maintained individually. In this example, the operator removes power to robot 3 stopping the robot. In doing so, the robots on either side of robot 3 reduce to a slower speed allowing the operator or maintenance person to work on robot 3. Production can continue at a slower rate in robot cell 2 and 4 and at full speed in robot cell 1 and 5. This solution offers a flexible strategy to carry out maintenance procedures while maintaining production.
- In this scenario we see an engineer programming a machine with multiple programming software tools. Programming safety control, plc control, drive control and other automation control with different tools may cause confusion, increase programming time and the possibility of programming errors. It also requires multiple software programmes to be learnt by the engineer and subsequently by the operating and maintenance staff.
- Here we see the engineer programming a machine through Rockwell Automations RSLogix 5000 software, a single programming environment for safety, drive, motion and plc programming. This reduces programming time and the possibility of errors by the engineer. It also aids programming consistency and flexibility, and when the machine has been deployed into the manufacturing environment it further reduces the possibility of error as the machine operator and maintenance engineer need only to learn one software platform.
- In this scenario we have the operator requiring access to a guarded area. Using lockout isolation techniques, electrical power and pneumatic power can be isolated to achieve a safety working environment inside the guarded area. In this situation the operator is locking out with padlocks which will then allow him to enter the guarded area with the keys in his pocket. In this senario the operator may need to go to several areas to lock off multiple power sources which may take time and also offers the possibility to forget to isolate some power sources.
- Here, a Prosafe key exchange system has been utilise for lockout which enforces a sequence of events before access to the guarded area can be achieved. The operator has goes to one location to isolate pneumatic power and electrical power with two A coded keys. When both keys are inserted into this key exchange system, key B is freed which can then be inserted into the door interlock. Key B is then trapped into the interlock which allows key C to be removed. The operator can put key C into his pocket and safely enter the guarded area. This solution enforces sequenced lockout of power and ensures that no power can be reenergised whilst the operator is in the guarded area.
- This scenario demonstrates the issues associated with low levels of integration and the impact this may have when production expansion is required. Here you can see one manufacturing line utilised within a factory. When demand increases, additional lines may have to be installed. The installation engineer has to program PLC, motion, drive and safety control individually, which lengthens the time it takes to increase capacity. This can impact time to market and cost of manufacturing integration.
- In this senario Rockwell Automations Integrated Architecture is utilised as the control platform which integrates safety and automation control in one environment. This allows the use of RSLogix 5000 software, a single programming environment for safety, drive, motion and plc programming. Manufacturing capability can then be easily and quickly replicated with the flexibility to individually adjusted settings within one environment.
- In this scenario a centralised monitoring facility for multiple manufacturing sites receives notification of unexpected nuisance tripping on one of its manufacturing lines. This may be due to a mechanical failure, environmental issues, or possibly a false alarm. Because there is insufficient diagnostic information to pinpoint the cause of the error, an engineer is sent to the plant. The engineer has to assess the whole machine to find the error and then take appropriate actions. This could be time consuming and costly. When assessing the machine, the engineer discovers it is a simple issue related to a safety light curtain which may have become misaligned due to vibration or un-intentional operator interaction. This process uses valuable maintenance time, can be costly and impacts on productivity.
- With a fully integrated solution utilising Integrated Architecture from Rockwell Automation, centralised monitoring of multiple plants is offers more comprehensive information to make appropriate decisions. Here you can see the centralised monitoring facility receives notification of unexpected nuisance tripping with specific information on the location and nature of the error. This allows monitoring personnel to contact the manufacturing site, inform local personnel who can then carry out appropriate actions to correct the fault. This reduces downtime, cost of maintenance and increases flexibility.
- In this scenario you can see that personnel are required to operate this loading cell. The operator is required to manually open the guarded access hatch, pass the barrel into the filling station and then close the guarded access hatch before the machine can commence filling. This process can limit productivity in relation to operator efficiency and also introduce possible operator error resulting in production waste. There is also the possibility of operators trying to bypass safety functions to increase throughput.
- In this senario, cross beam muting and safety light curtains are used with a conveyor belt to automate a filling station process. The barrels are preloaded onto pallets which move along the conveyor belt. As the pallet mounted barrel passes through the two cross beam sensors, the light curtain is automatically muted to allow the barrel to pass into the guarded area. When it clears opposing two beams, the light curtain un-mutes which reengaging safe guarding of the access hatch and allows the barrel to be filled. This automated system increases productivity and reduces the possibility of operator error whilst ensuring that the hazardous area is guarded at all times.
- In this senario an operator requires access into a production cell protected by an interlocked guard door. The operator gains access by opening the guard door without initiating a controlled machine stop, an incorrect but common operator action. This removes power from the application to allow safe access but also may remove all power to the AC drives via the up-steam safety contactors utilised in the application. Upon restart of the application the AC drives have to power cycle which may take time and also is detrimental to the operational life of the drives. Complex start-up routines may also have to be followed which could result in product waste.
- In this senario an operator requires access into a production cell protected by an interlocked guard door. The operator gains access by opening the guard door without initiating a controlled machine stop, an incorrect but common operator action. The PowerFlex AC drives in this application have integrated Safe Torque Off which removes rotational power to the motors. This allows power to be maintained to the AC drves but ensures the application can not start. When the operator closes the guard door and initiates application restart, no power cycling or complex start-up routines are required, allowing production to quickly return to full speed. Safe Torque Off also allows system complexity to be reduced as up-steam safety contactors can be removed
- This senario illustrates the complexity a control system may reach when line expansion is required. A large control cabinet is required to house all control functions such as PLC, drive, motion and safety control with associated devices. As devices are added to the production line such as safety devices, sensors, indicators and machine control devices, system complexity and wiring increases. Utilising traditional connection solutions and separate control for automation and safety, the control system can quickly become challenging to maintain and troubleshoot. Premium space with associated costs is also required to house large control cabinets.
- Utilising an integrated safety solution based on GuardLogix allows automation and safety control in one platform which helps reduce control cabinet complexity and size. Distributed safety I/O’s also allow localised control on the machine, further reducing the necessity to have all control functions in one location. The use of CIP safety over EtherNet/IP or DeviceNet, allowing standard and safety communications to exist in one network further reduce wiring complexity and simplifies maintenance. Therefore it becomes clear how a control system can be simply expanded without impacting space requirements and complexity.
- In this scenario you can see the impact total power removal has when maintenance procedures such as cleaning are required on a printing press. The operator removed power to the press in order to gain access inside the guarded area. Only partial cleaning can be achieved in this state as the rollers can not be rotated to completely clean them. When the rollers need to be rotated to complete cleaning, the operator must leave the guarded cell to initiate partial rotational power. To complete cleaning, this procedure may have to be repeated a few times. This impacts the time it takes to complete cleaning and lengthens the machine downtime.
- In this senario Safe-speed control technology from Rockwell automation is utilised to allow efficient maintenance of a printing press. The operator sets the machine into maintenance mode which allows safety monitored partial power to be available. The operator can then enter the guarded area and using a 3 position grip switch, can safety engage slow movement of the rollers at a pre-determined safe limited speed. This allows the operator to carry out cleaning efficiently and quickly resulting in minimum machine downtime. Safe direction can also be utilised to rotate the rollers in an outward moving direction, thus removing potential pinch points. If at any stage the operator needs to stop the rollers, he can either let go or squeeze the 3 position grip switch.
- In this senario you can see the effect a pre-determined timed delay has on operator access to a machine. The operator selects a controlled stop to allow him to gain access through the interlocked guard doors. The machines saw blades coast to a stop placing the machine in a safe condition. Access however to the guarded area is not allowed until the safety system, utilising a pre-determined delay function, unlocks the guard door. This may be lengthy as the machine builder may have included a safety factor in assessing the required stopping time of the machine, hence extending the time to unlock the guard door. If frequent access is required this could impact the machines productivity.
- In this senario Safe-speed control technology from Rockwell Automation is utilised to allow operator access into a hazardous area as soon as a safe condition exists. The operator selects a controlled stop to allow him to gain access through the interlocked guard doors. The machines saw blades coast to a stop placing the machine in a safe condition. As soon as the the hazardous motion has stopped, the safe-speed monitoring function signals the guard doors to unlock allowing the operator to gain immediate access. If frequent access is required this could help reduce machine downtime and increase productivity.
- In this senario an application is shown that requires travel velocity to be accelerated and decelerated under control. With a control system without safe-speed monitoring, there is potential of speed adjustments being made by an engineer or fault conditions that could result in ride quality issues. Here you see a chair lift with deceleration speed issues at the unload area causing the chair to swing. Similar issues could also be found in conveyor applications on start-up and stopping which could cause product movement issues or runaway conditions.
- In this senario Safe-speed control technology from Rockwell Automation is utilised to safely monitor maximum acceleration and deceleration. This allows the control system to stay within tolerances set by the application engineer. If changes are made to velocity or a fault occurs the safe-speed monitor will take appropriate action. This allows control of ride comfort safely. This senario is shown utilising the MSR57P safe-speed monitoring relay but is also available as an integrated option into the PowerFlex 750 series of AC drives and future release of Kinetix 6000 motion drives from Rockwell Automation.