DS-JUL24-PG12+13_Layout 1 16/08/2024 11:43 Page 1
ADVERTISEMENT FEATURE COVER STORY WHY SAFETY SHOULD NO
In the rapidly evolving industrial landscape, where efficiency and productivity are paramount, the role of safety in machinery design has never been more critical. Gone are the days when safety was an
afterthought, tacked onto a machine design once the primary engineering was complete. Today, safety must be embedded in the very DNA of
machinery design, from the earliest conceptual stages. This shift is not only a response to more stringent regulations but also a necessary
adaptation to the complexities of modern manufacturing environments, where downtime is costly and often unacceptable. David Dearden, from machinery safety specialists Euchner, gives valuable insight to equipment builders to ensure compliance in their design
THE CHANGING LANDSCAPE OF MACHINERY DESIGN
become more sophisticated, interconnected, and integral to broader process systems. This evolution has introduced new challenges in maintaining safety without sacrificing productivity. • Integration with Complex Process Systems: Modern machinery often operates as part of a larger, integrated production line where even a minor disruption can lead to significant losses. In such environments, simply shutting down a machine for the reloading of consumables is not a viable option. The entire production line must keep running to avoid unacceptable waste, making continuous operation a critical consideration in design.
O
• Operator and Maintenance Interaction: The role of machinery operators and maintenance personnel has significantly transformed with the shift from cyclical production to continuous processes. In the past, operators could afford to stop machines during maintenance or adjustments without impacting the overall production flow. However, in today’s environment, where machinery operates as part of an interconnected, continuous process, stopping a machine can halt the entire production line, leading to costly downtime. As a result, there is a growing need to design machinery that allows operators to interact safely with moving, working equipment. This interaction is made possible through advanced safety features such as hold-to-run controls, which enable the machine to operate at reduced speed or pressure, ensuring that safety is maintained even during ongoing operations or more basic design characteristics such as bringing lubrication points outside of the machinery guarding. These innovations allow for necessary interventions without compromising the overall productivity of the process.
ver the past few decades, the nature of machinery design has undergone significant transformations. Machines have
• Compliance with Safety Standards: Adhering to recognized safety standards, such as EN ISO 12100:2010 (Safety of machinery – General principles for design – Risk assessment and risk reduction) and EN ISO 13849-1:2023 (Safety of machinery – Safety-related parts of control systems), is crucial in today’s regulatory environment. These standards provide a framework for integrating safety into the design process, ensuring that machines meet stringent safety requirements while maintaining operational efficiency. - EN ISO 12100:2010 outlines a systematic
approach to identifying hazards, assessing risks, and reducing those risks through design modifications or protective measures. By following this standard, designers can ensure that all potential hazards are addressed early in the design process. - EN ISO 13849-1:2023 focuses on the safety-
THE IMPORTANCE OF EARLY SAFETY CONSIDERATION
With the increasing complexity of industrial machinery and the need for uninterrupted operation, safety can no longer be an afterthought. Incorporating safety into the earliest stages of design is crucial for several reasons: • Proactive Hazard Identification: By considering safety from the outset, potential hazards can be identified and mitigated before they become ingrained in the design. This proactive approach allows designers to address risks systematically, ensuring that safety is not compromised at any stage of the machine's lifecycle. As an example, a designer could change from a spoked drive wheel to a solid version, removing the shearing hazard completely.
12 DESIGN SOLUTIONS JULY/AUGUST 2024
related parts of control systems, particularly how these systems perform their intended safety functions under various conditions. This standard is essential for ensuring that safety mechanisms, such as emergency stops and interlocks, are reliable and effective throughout the machine's operation.
• Integration of Advanced Safety Solutions: Early consideration of safety allows for the seamless integration of advanced safety solutions that are essential for modern machinery. For instance, ‘hold-to-run’ controllers can be implemented to enable machines to continue operating at reduced speeds or lower risk levels when maintenance or adjustments are necessary. These controllers require the operator to maintain constant pressure on a control device, ensuring that the machine stops immediately if the operator releases it, thus providing a fail- safe mechanism during critical operations.
• Key-in-Pocket Systems offer another innovative safety solution. These systems involve the operator taking a physical key inside the machine when entering for maintenance or troubleshooting. The key must be in the
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64
