Feature Machine safety
Safety control projects across multiple sectors
Optima Control Solutions experts design and build safety control systems for a variety of industries including paper, plastics and metals. Recent projects include API’s laminating line in Poynton, a safety critical application at Dunlop Oil & Marine and a safety control system for papermaking, coating and converting company Tullis Russell
Top right: Optima Control Solutions refurbished a production machine for Dunlop Oil & Marine in order to meet strict safety standards
Optima Control Solutions upgraded a safety control system for Tullis Russell in Scotland
F
or API’s laminating line in Poynton, Optima replaced the single channel emergency stop push buttons and guards with a dual circuit system. Six new lockable guard switches were fitted on the machine. A safety ‘motion detection system’ was included using star wheel plates and rotation detection proxim- ity switches fitted on two DC motor driven rollers.
The redundant safety system was designed to ensure that if one contactor failed to open and remove the mains supply, a backup contactor would
ensure the supply is removed. Designing machine safety systems needs due con- sideration of machine operability. The use of a programmable safety PLC (Pilz) allowed the flexibility for machine oper- ators to enter some sections of the machine without compromising the integrity of the machine safety circuit. API’s engineering manager Tony Robinson says: “Optima did a high quality job, on time and within budget - which is why we have used them before and will use them again. They have been excellent.” In another, equally safety critical
Optima provided a safety control solution for API’s laminating line in Poynton
application at Dunlop Oil & Marine, Optima was to refurbish one of its main production machines to improve its control and reliability, and to meet the stricter safety standard of EN13849. The project required Optima’s engi- neers to work with their Dunlop coun- terparts to design a complex, yet flexible, safety system, which could also monitor the rate of motion under various operational conditions. Optima selected the Pilz PNOZ Multiprogrammable safety relay to enhance the security of the machine and extend its lifetime. It also used Siemens’ Simotion D drive to precisely gear-lock the machine’s carriage drive, which applies the material to the main drive. Optima MD Michael Hill says: “By using the latest Siemens and Pilz technology we successfully enhanced the safety, security and lifetime of Dunlop’s machine, therefore eliminat- ing a major risk factor.”
Optima Control Solutions T: 01254 272829
www.optimacs.com Enter 317
Emergency stop button illuminates red and yellow B
anner’s patent-pending 30mm Mount Illuminated Emergency Stop pushbutton, combines status indication and safety in one. With bright, highly-visible illumination, the new E-Stop is suitable for diverse emergency stop safety applications, helping provide users with enhanced safety and productivity on the manufacturing floor. Featuring Banner’s EZ-LIGHT logic, the 30mm Mount E-Stop pushbuttons provide an illumi- nated yellow base when the button is armed and the machine is enabled to RUN or is running.
When the button is pushed, the yellow illumination turns to a flashing red indication to alert operators of an emergency stop condition. Users can easily reset only the pushed button or buttons, readying the device efficiently with minimal downtime. The yellow illumination can also turn to a steady red indication when a ‘stop’ condition exists by applying an external signal. The E-Stops are available with two-color yellow and red lighting, red lighting or a non-illuminated black base. Turck Banner
T: 01268 578888
www.turckbanner.co.uk Factory Equipment NOVEMBER/DECEMBER 2012
Enter 318
Another business for which Optima upgraded a safety control system was the papermaking, coating and converting company Tullis Russell in Scotland. For this project, Optima inte- grated a Siemens PLC and HMI, Parker SSD drives, ABB tension control, Pilz safety equipment and Sick optics, sub- sequently elevating the machine’s pro- ductivity. The emergency stop system was designed to suit a risk level SIL 2. A Pilz PNOZ Multi programmable safety relay system was also used for this application. Hill says: “When con- sidering a control system upgrade safety improvements are unavoidable and are a fundamental component that keeps the machine running.”
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