FEATURE MACHINE BUILDING, FRAMEWORKS & SAFETY
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THE EVOLUTION OF MACHINERY SAFETY: BALANCING INNOVATION
WITH COMPLIANCE Mark Staples from EUCHNER in the UK explores key milestones in machinery safety, the
transformative role of digital systems and
communication protocols, and what lies ahead for designers, manufacturers, and end-users
years, safety solutions have evolved from mechanical systems to advanced digital technologies tailored to modern manufacturing needs. Today, the focus is on achieving the delicate balance between embracing innovation and ensuring compliance with ever-changing regulations and standards.
M
INNOVATION AND COMPLIANCE The rapid pace of technological innovation in machinery safety brings both opportunities and challenges. Smarter, more adaptable systems enhance operational efficiency and safety, but aligning these advancements with the latest regulations and standards demands vigilance. New European regulations now incorporate requirements for areas like artificial intelligence (AI) and cybersecurity. Meanwhile, standards such as BS EN 13849-1 set the benchmark for achieving the necessary safety integrity levels. For designers and engineers, staying informed and proactive is not just advisable – it is essential.
BRIDGING THE GAP BETWEEN TECHNOLOGY AND REGULATION Ensuring machinery safety compliance requires understanding both regulations – mandatory legal requirements – and standards, which provide best practices for achieving safety. With emerging technologies like RFID systems and advanced communication protocols, the challenge lies in aligning these innovations with existing frameworks. Standards such as BS EN ISO 13849-1 guide engineers on assessing and achieving safety performance. However, applying these standards to rapidly evolving technologies requires significant expertise. Moreover, recent European regulations extend beyond physical safety, incorporating provisions for cybersecurity and AI. Cybersecurity, in particular, is a pressing concern as connected safety systems become vulnerable to cyber threats that could compromise their reliability. Conducting thorough cybersecurity risk assessments and implementing safeguards is vital to maintaining both compliance and operational integrity.
achinery safety has long been central to industrial design, protecting both operators and equipment. Over the
LEARNING FROM THE PAST TO SHAPE THE FUTURE The history of machinery safety offers valuable lessons for engineers and designers. Decades ago, single-contact safety interlocks were commonly used on high-risk machinery. While this approach was acceptable at the time, advancements in technology and the introduction of standards like BS EN 13849-1 have significantly raised the bar for safety systems. What was once standard practice would now be deemed insufficient under today’s regulatory and technological
landscape.This evolution underscores the importance of incorporating modern safety requirements into designs now rather than waiting for regulations to make them mandatory. Delaying these updates risks costly retrofitting and missed opportunities to enhance safety and efficiency.
COMPETENCE IN COMPLIANCE Meeting modern safety standards requires more than just technical solutions; it demands a deep understanding of the regulatory landscape. This is where EUCHNER can assist. Offering a comprehensive range of accredited training courses, EUCHNER equips engineers, designers, and manufacturers with the knowledge they need to address modern safety challenges. Topics covered include interpreting BS EN ISO 13849-1, navigating cybersecurity risks, and integrating AI into safety systems. These programs empower industry professionals to stay ahead of regulatory changes and leverage innovative solutions confidently.
ADAPTING MACHINERY SAFETY FOR MODERN NEEDS Mechanical safeguards, such as trapped key interlocks, continue to play a vital role in machinery safety today. These systems ensure safe access to hazardous areas by physically preventing entry to active equipment. Their
20 DESIGN SOLUTIONS NOVEMBER 2024
reliability and robustness make them a trusted solution across industries. However, modern manufacturing environments often require greater flexibility and scalability. For these applications, digital safety systems, particularly those using RFID technology, offer advanced solutions. RFID systems provide user- specific access control, enhancing security and reducing the risk of bypass. By integrating with control networks, they also enable real-time diagnostics, improving downtime management and operational efficiency. Furthermore, lost RFID keys can be quickly replaced while disabling the missing key, ensuring safety without operational disruption. By combining the dependability of traditional mechanical safeguards with the adaptability of digital systems, manufacturers can address the complexities of today’s industrial processes while maintaining high safety standards.
FIELDBUS PROTOCOLS Modern machinery has also moved beyond traditional
hard-wired safety systems, which were labour-intensive and inflexible. Today, advanced communication protocols such as IO-Link Safety, PROFINET PROFIsafe, EtherNet/IP CIP Safety, and Safety-over- EtherCAT streamline safety communication. These protocols consolidate multiple signals onto a single cable, simplifying installation and reducing costs while ensuring real-time data exchange for safety-critical operations. Fieldbus systems provide scalability, enabling modular upgrades and seamless expansions without extensive rewiring. They also offer integrated diagnostics, which support predictive maintenance and faster fault resolution, making them indispensable for modern machinery safety.
ACTING TODAY FOR A SAFER TOMORROW As machinery safety continues to evolve alongside technological advancements, the responsibilities of engineers and designers grow increasingly complex. Incorporating the latest regulatory and standards requirements – such as those for AI, cybersecurity, and advanced safety functions – has become essential for creating compliant and future-ready designs. By staying informed and utilising resources
like EUCHNER’s training programs, manufacturers can confidently navigate these challenges. Combining innovative solutions with a commitment to compliance will ensure safer workplaces, more reliable operations, and a stronger foundation for the future of machinery safety.
EUCHNER T: 0114 256 0123
sales@euchner.co.uk
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