taktik(z) | leuze electronic | safety training
DESCRIPTION
taktik(z) | Leuze electronic | Safety TrainingTRANSCRIPT
Mark Smokowicz / LAS
Safety Training
Mark Smokowicz
Leuze electronic
Product Management & Safety Products PM
Mark Smokowicz / LAS
What is covered today?
• Common safety standards– differences in standards
• What is Safe Distance?• Reach over and under• Some definitions• Safety Distance calculations
– OSHA, EN999, ANSI-RIA
• Safe distance example• Introduction to Risk Assessment• Application example• Questions to ask
Mark Smokowicz / LAS
Common Safety Standards
• Occupational Safety and Health Administration– (OSHA) 1910 Machinery and Machine Guarding
• American National Standards Institute– (ANSI) B11.19 Performance Criteria for Safeguarding
• Robotic Industries Association – (RIA) R15.06 Robot Safety Standard
• American Society of Mechanical Engineers– (ASME) B15.1 Safety Standard for Mechanical Power Transmission
• European Standard– (EN954) Safety of Machinery
• Canadian Standards Association– (CSA) Z434-03 Industrial Robots and Robot Systems
General Safety Requirements
Acronyms:OSHAANSIRIAASMEENCSA
Mark Smokowicz / LAS
What is safe distance?
A method of work piece positioning and operator location that eliminates the need for the operator to be in our near the hazardous area during the hazardous portion of the machine cycle
CSA Z 432-04 Safeguarding of machinery – ANSI B11-19-2003
All safeguarding devices shall be securely installed and located at a distance such that the hazard cannot be accessed.
CSA Z 432-03 Robots – ANSI RIA R15.06-1999
Mark Smokowicz / LAS
Safety Distance and Barriers
The barrier (and any barrier openings) needs to be sized such that a person cannot reach:
»Over»Under»Around»Through
and access a Hazard
The same for US, Canada and Europe
Mark Smokowicz / LAS
“Reach Over” – “Reach Under”
CSA Z434 clause 10.2ANSI-RIA R15.06
Barrier Guards
CSA Max: 6”ANSI RIA Max: 12”
1.8m (72”) CSA min
CSA Clearance: 20”ANSI RIA Clearance = 18”
1.5m (60”) RIA min
Mark Smokowicz / LAS
Safety Distances
U.S. Safety Distance Formulas
Safety Light Curtains must be mounted at a sufficient distance from the pinch point or point of operation hazard to ensure that the machine stops before a person’s hand(s), arm(s), or body reaches the hazard. This distance, referred to as the safety distance, must be properly calculated prior to determining the safety light curtain protective height and mounting the light curtains on the machine. Failure to properly calculate this safety distance may result in operator injury.
Note: Regardless of the calculated safety distance, Safety Light Curtains should never be mounted closer than 6 inches from the point of operation or pinch point hazard. ref. EN999 100mm min (4”)
In the United States there are two formulas that are used to properly calculate the safety distance. The first, the OSHA formula, is the minimum requirement for the calculation of the safety distance. The second formula, is the ANSI formula, which incorporates additional factors to be considered when calculating the safety distance.
Mark Smokowicz / LAS
Dpf Depth Penetration Factor
• Maximum travel towards the hazard within the presence sending safeguarding devices (PSSD) field that may occur before a stop is guaranteed
• It is possible that you can reach through the light curtain a SHORT distance
• Depth penetration factors will change depending on the resolution of the device or minimum object sensitivity (OS)
Acronyms:AOPDPSSDOS
Mark Smokowicz / LAS
Resolution of AOPD
Resolution (d) = pitch (p) + lens diameter (Ø)
d = p + ØChannel
p Ø
Channel
Resolution (d) AKA Object Sensitivity (Os)
Mark Smokowicz / LAS
Dpf, Depth Penetration Factorbased on ANS-RIA
Light Curtain
Light Grid
Mark Smokowicz / LAS
Dpf, Depth Penetration Factor(OS) < 2.5”, Vertical Field
PSSD
Resolution
(mm)
Dpf
(mm)
Dpf
(in)
14 24.22 .95
20 44.62 1.75
30 78.62 3.09
40 112.62 4.43
For ANS-RIA, CSA
Mark Smokowicz / LAS
Safe distance calculations
Ds = 63 x Tswhere:
• Ds = min safe distance between safeguarding device and the hazard (inches)
• 63 = constant, speed of hand/arm when body is stationary, use 63 in/s
• Ts = total stopping time of all the devices in the safety circuit, measured in seconds.
OSHA version
Mark Smokowicz / LAS
Safe distance calculations
Ds = K x (Ts + Tc + Tr) + Dpfwhere:
• Ds = min safe distance between safeguarding device and the hazard (inches)
• K = constant, speed of hand/arm when body is stationary, 63 in/s
• Ts = stopping time of the machine/equipment (wc)• Tc = stopping time of the control system (wc)• Tr = response time of the safeguarding device and
it’s interface• Dpf = Depth penetration factor
ANSI RIA version
Mark Smokowicz / LAS
Safe distance calculations
S = (K x T) + Cwhere:
• S = min safe distance between safeguarding device and the hazard (mm)
• K = constant, speed of hand/arm when body is stationary, use 2 m/s
• T = t1 + t2 + t3• t1: response time of the AOPD• t2: response time of the safety interface• t3: response time of the machine
• C = 8 x (d-14)• d = resolution of the AOPD (14 to 40mm)
EN99 version
Mark Smokowicz / LAS
Safe distance calculations
Ds = 63 x Ts
Ds = K x (Ts + Tc + Tr) + Dpf
S = (K x T) + C
What to do….so , let’s see the differences?
OSHA ?
ANSI ?
EN ?
Mark Smokowicz / LAS
Safe distance calculations
Example:
A light curtain application has;o a response time of 15 ms
o a machine stopping time of 180ms
o braking response time of 40ms
o and a 3.2 inch depth of penetration
Assume a 14mm resolution device
Let’s divy this up, solve and compare
Mark Smokowicz / LAS
Stopping distance examples
ANSI versionDs = K x (Ts + Tc + Tr) + Dpf
OSHA version Ds = 63 x Ts
EN999 version S = (K x T) + C
Example:A light curtain application has; a response time of 15 ms, a machine stopping time of 180ms, braking response time of 40ms and a 3.2 inch depth of penetration
Ds = 18.0”
Ds = 14.8”
S = 18.5”
Mark Smokowicz / LAS
Stopping distance examples
14.8
18.5
18
0 5 10 15 20
EN999
ANSI-RIA
OSHA
Mark Smokowicz / LAS
Calculating min Safe Distances
S
Channel
Stepping behind protectionusing master and slave units(different resolutions possible).
Minimum Safe Distances must be calculated for each segment.
Mark Smokowicz / LAS
Safeguarding devices used horizontallyDirection of approach parallel to the sensing plane of the AOPD
SChannel
H*
d
Relationship between height of the sensing plane above ground and resolution of the AOPD: d = resolution of the AOPDH = height of the AOPD above ground
H = 15 x (dmax - 50) [mm]
dmax = H/15 + 50 [mm]
Minimum safety distance S:
S = K x T + C
K = 1.6 mm/ms
T = tAOPD + tInterface + tMachine in ms
C = (1200 + 0.4 H) in mm
H < 1000 mm
H < 300 mm is considered not to allow crawling underneath
(< 850 mm)
Using EN999
Mark Smokowicz / LAS
Mark Smokowicz / LAS
Area Scanner Safety Distance
S = (K x T) + C
C = 1200 – 0.4 x H in mmCmin = 850 mmSFT = Depth of protection field
Hmin = 15 x (d - 50)
H = Heights of scanning plain d = Resolution of AOPDDRd = 70 mmHmin = 300 mm
Hmax = 1000 mm
S HSFT
S = Safety distance in mmK = 1.6 mm/msT = tAOPDDR+tInterface + tMachine in ms
EN-954
Mark Smokowicz / LAS
Web based tools
Mark Smokowicz / LAS
Calculation wizards
Mark Smokowicz / LAS
Introduction to Risk Assessment
Mark Smokowicz / LAS
Safety related parts of machine controlEN 954-1
operator-machineinterface
hard
guarding
signallingdisplaywarning
actuatorscontroldevice
data storageand logic or analogue
data processing
powercontrol
elements(contactors, valves, etc.)
sensors,safety devices
machine actuators(engines, cylinders)
power transmission elements
working parts
General schematic representation of a machine
Mark Smokowicz / LAS
Risk reduction
risk level
maximally permissible riskrisk without anysafety measures
remaining risk
part of risk reduced by design measures
risk without safety relatedparts of machine control
necessary reduction of risk
part of risk reduced by safety related parts of control
real reduction of risk
Mark Smokowicz / LAS
Risk elements
Riskreferring to the considered danger
Probabilityof damage occurrence:
- frequency and duration of the danger exposure
- possibility of avoidance or limit of damage
Probabilityof damage occurrence:
- frequency and duration of the danger exposure
- possibility of avoidance or limit of damage
and
Severitythe possible damage by theconsidered danger
is afunction
of
Mark Smokowicz / LAS
Risk elements
• slight• severe
severity of the injury
• rarely, short • frequent, long
exposure in danger area
• possible• rarely possible
possibility of avoidance
Mark Smokowicz / LAS
Risk levels
Severity of injury
S1: slight injury (reversible)
S2: severe irreversible injury or one or more
persons or death of a person
Frequency, duration of exposure
F1: rarely to repeated and/or short duration
F2: frequent to permanent and/or long duration
Possibility to withhold from exposure to hazard
P1: possible by certain conditions
P2: rarely possible
Sev
erit
y o
f in
jury
Fre
qu
enc
y, d
ura
tio
n o
f ex
po
sure
Po
ssib
ilit
y to
wit
hh
old
S1
S2F1
F2
P1
P2
P1
P2
I
II
III
IV
V
EN 954-1
Mark Smokowicz / LAS
Risk reduction indexCSA Z434-03
Mark Smokowicz / LAS
Safeguard selection matrixCSA Z434-03
Mark Smokowicz / LAS
Example
The dangerous event is the uncontrolled movement of the press from standstill or a delayed stopping of the machine.
This event can cause severe injuries or at worst, lead to death.
In this example, it is assumed that the user stays frequently in the danger zone.
Since the pressing is a very fast process, the dangerous situation can hardly be avoided.
Category: _____Category: _____
Result:S1
S2F1
F2
P1
P2
P1
P2
B 1 2 3 4
EN 954-1
Mark Smokowicz / LAS
Types of AOPD applications
Making a danger point safe
Access guarding
Safeguarding an area
Perimeter guarding
Mark Smokowicz / LAS
Questions to ask
• To determine resolution to use– Finger safe 14/20mm– Hand safe 30/40mm– Access/area 50/90mm, multibeam,
laserscanner• What are you interfaced to?
– Solenoid/starter relay output– Safety PLC pnp safety outputs
• Special functions required?– Muting integrated muting lamp, sensors– Interlocks safety switches
• Cables, special mounting considerations?– High vibration anti-vibration brackets– Washdown applications IP68 tubes– Ease of wiring MIN connectors/cables
Mark Smokowicz / LAS
What was covered today?
• Common safety standards– differences in standards
• What is Safe Distance?• Reach over and under• Some definitions• Safety Distance calculations
– OSHA, EN999, ANSI-RIA
• Safe distance example• Introduction to Risk Assessment• Application example• Questions to ask
Mark Smokowicz / LAS
Thank You for Your Interest in Safety Products of
Leuze electronic