machinery safety system selection and development

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Machinery Safety System Selection & Development


Agenda

Types of Safety Logic Systems

Safety Logic System Functionality and Purpose

Introduction

Market Segments

Differences in Safety Logic Systems

Determining the Best Safety System for You

How Rockwell Automation can Help


Session Purpose and Intent

This session is meant to outline the steps of selecting &

developing machinery safety solutions.

Additional sessions (SF01, SF02, SF04 & SF05) break

this process down in more detail.


Agenda



Introduction

Market Segments





5

SENSOR

CONTROL SYSTEM

Connection systems

Sensors

[e.g. Interlock switch]

LOGIC SOLVER ACTUATOR

Logic Solver [e.g. Modular Relay]

Logic Solver [e.g. Programmable Controller] Networks

Actuators

[e.g. Contactors]

Distributed Inputs

Distributed Outputs

Actuators

[e.g. Servos, Std. Drives]

Rockwell Automation has the broadest portfolio of safety sensors, safety logic systems, and safety actuators in the market!

Safety System Components


Safety Logic Devices

Safety Logic Devices

SENSOR

CONTROL SYSTEM

LOGIC SOLVER ACTUATOR

Safety Logic devices monitor the status of safety input devices, make decisions, and control the safety output devices.


Monitoring

Control

Diagnostics

Logic Functionality


Agenda



Introduction

Market Segments





There are 3 safety logic architectures

that can be used to provide safety

control

Dedicated Relay

Modular Relay

Safety PLC or Controller

Safety PLC & Safety Controllers

Modular Relay

Dedicated Relay

Inputs Outputs Base

Safety Logic Architectures


Rockwell Automation Scalable Safety Solutions

Integration Continuum

Offering solutions that fit your needs, not ours!

Cost-effective Component Solutions Mid-Range Solutions Integrated Solutions

Low High

Simple connectivity Mechanical linked machine

Stand alone machine Low cost

Just enough control

Multi-axis motion Increased controller capabilities

Mix of mechanical and electrical controls Low engineering costs

Coordinated multi-axis motion Robotic feeders

Electronic line shafting Advanced connectivity

Advanced information capabilities

Components Integrated Architecture

10 10


Agenda



Introduction

Market Segments





Safety Market Segmentation

30% of respondents use contemporary/integrated safety solutions.

Source: Control Design Magazine Survey, June 2009

30%

• The largest market for safety products is with the low to mid range OEMs.

70% use hard-wired relay-based safety systems.


Cutting & slicing Machines

Shrink Wrappers

Form Fill & Seal Machines

Food & Beverage Bottle labeling

Integrated Bottling Lines

Safety Market Segmentation

High end safety Low end safety

30% of the market

Low end safety relay market

Mid-range safety

40% of the market 30% of the market

Mid level safety relay & controller market

High level safety controller market

Palletizers & De-palletizers

Case Packer Systems


Agenda



Introduction

Market Segments





Low Complexity Safety Systems

Cutting & slicing Machines

Shrink Wrappers

Low end safety

Low end safety relay market

40% of the market

Tend to use Micro controllers and simple safety relay solutions with 1 zone of control & little to no motion control:

Simple safety input monitoring and power isolation

Simple safety input monitoring and drive control

Benefits: • Low cost • Simple installation • Just enough control for small

applications • Easy diagnostics at the relay


Mid-level Complexity Safety Systems Require more than stand alone control but need low cost solutions. These systems typically have 25 to 100 points of I/O, 2 to 3 zones of safety control, 2 to 6 axes of motion control, and 2-6 screens of visualization.

Modular and expandable relay systems that are capable of multiple zones of control

Form Fill & Seal Machines

Mid-range safety

30% of the market

Mid-level safety relay & controller market

Palletizers & De-palletizers

Case Packer Systems

Safety Controllers that have network and zone control capability

Benefits: • Low to medium cost • Simple installation • Just enough control for the application • Easy diagnostics at the relay and HMI • Expandable • Networkable • Can do some zone control

http://epub1.rockwellautomation.com/images/gl2/33287.jpg


High Complexity Safety Systems

Food & Beverage Bottle labeling

Integrated Bottling Lines

High end safety

30% of the market

High level safety controller market

Solutions in the high end market tend to be solutions that are large, complex and integrated. These systems often have multiple zones of control, distributed I/O, multiple axis of motion control, high I/O counts and complex safety needs.

Benefits: • Scalable • Networkable • Modular • Easy diagnostics via

communications to a common HMI screen.

• Expandable • Flexible • Productivity Gains • Efficiency Gains


Shared assets across standard & safety control drive cost savings and add significant value throughout the manufacturing process.

High End Safety Systems are also known as Integrated & Contemporary Safety Systems!

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 9/9/2011

The New Standards Allow the Use of Contemporary Safety

Solutions that Provide Better Solutions for Customer Needs!

We use the term contemporary because it is a change in the way safety systems have been applied & integrated in the past. Safety was an add-on to the control system. Contemporary safety solutions are embedded into the design thus becoming a part of how the machine operates. Examples of contemporary solutions are described below:

Safe speed – This allows for minor machine servicing like adjustments, feeding, cleaning & wash-downs without shutting the machine down because the machine is operating at a speed that deemed to be safe (Less than 250mm per second).

Safe direction – This allows for cleaning & adjustments because the hazard has been removed by reversing hazard causing motion.

Safe position – This allows for interaction with equipment as long as the hazard is in a safe position/location.

Zone control – This allows for parts of a machine to operate while other pieces to continue operation thus reducing scrap & waste.

Advanced diagnostics – Contemporary safety solutions typically have better diagnostics because the standard and safety control are in 1 control system. This allows for better MTTR (Mean Time To Repair).

Distributed I/O – (Both safety and standard). This allows for modular designs that can be broken down for quick shipping and re-assembly at customer locations.


Contemporary Safety Brings Things Together!

ControlLogix chassis

PowerFlex 755

Armor Block I/O

EtherNet/IP

PV+ EOI

Safety Relay

Safety Relay

Stratix 8000

ETAP

POINT I/O

Safety System

An ethernet switch may

not be required.

Safety functionality can now be integrated

into GuardLogix.

Data & diagnostics

can be displayed on

one HMI.

Benefits

Information enabled. Fewer components. Less training. Streamlined maintenance. Optimal connectivity with multiple networks.

Kinetix 6000

DeviceNet

Safety relays & contactors may not be required.


Communication & Coordination Logic

Standard Controller

Motion Controller

Safety Controller

Software

Logic

Integrated Safety Controller

Control

Integrated safety solutions reduce engineering and design times by 20 to 30%! Integrated safety solutions reduce trouble-shooting times by 25% Integrated safety solutions improve productivity by 3 - 5 % (1% productivity = $250K - $2M)

Competitive vs. Rockwell Automation Solutions

Software

Logic


Agenda



Introduction

Market Segments




Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 23

How Do I Determine the Best Safety System for Me?


Follow the Safety Life Cycle!

5. Operate, Maintain and Improve 1. Assessment

4. Installation and Validation 2. Functional Safety System Requirements

3. Design and Verification

Identifies Task & Hazards Pairs

Circuit & Component Selection Safety System Design Design Verification Guarding design

Outlines functional requirements of the safety

system

Final site assembly Commissioning Validation Final Assessment Validation

Detailed operational specification Required maintenance schedule Preventive maintenance schedule

The Safety Life Cycle Helps You Determine System Requirements & Needs!

Steps 1 & 2 help to define system requirements prior to the selection &

design process!


Step 1: Do a Risk Assessment!

ISO-13849-1 identifies a risk assessment as the means of determining

risk levels, associated risk reduction methodologies, and the type of

safety system performance that needs to be implemented.

Risk assessments also help identify each hazard that needs to be

safeguarded.

S1

S2

F2

F1

a

b

P1

P2

e

c

d

P1

P2 P1

P2

P1

P2

F2

F1

b

c

d


Step 2: Develop a Functional Specification!

A Functional Safety Specification helps determine the proper safety

function needed to protect people from each hazard on the

machine/system.

Functional specifications determine the following:

Safety system needs for each mode of operation.

Safety function(s) needed to mitigate each hazard/risk.

Safety system structure & technologies (Zones/Safe Speed/Safe

Direction).


My assessment & requirements spec sure made this easy!

Step 3: Design & Selection Considerations!

Design considerations: • What mitigation technique should I use? • What circuit structure should I use? • What safety products should I use? • What type of control system should I use?

(Relays/Controllers/PLC’s) • What type of special operations do I need?

(Zone control/Safe-speed/etc.) • Where are all of my safety devices? • What kind of interactions are needed for

auxiliary machines? • What kind of diagnostics do I need? • Should I use hardwiring or networked

systems?


Additional Factors in Determination of Design

Category, PL, or SIL level requirement

Functional requirements

Compatible interfaces to sensors and actuators

System size / footprint

System complexity – Logic Requirements

Process complexity

Zoning requirements

Safety Monitoring / Diagnostics / Information

Documentation, Validation, Reporting

Cost


Cultural Factors that Drive Relay and Controller Selection!

1. Customer does not use automation

products

2. Customer’s Maintenance staff does not

use PCs and is not software literate

3. Customer not clear on how safety

systems will impact his business, plant,

machinery, or processes

4. Customer very happy with SLCs,

Micrologix or similar low end PLC

solutions

1. Customer is a sophisticated user of automation

2. Customer Uses Integrated Architecture / Logix

3. Customer has challenging applications and can deal with overhead to “get started”

4. Customer has numerous potential applications and wants to maximize productivity

Safety Relay Solutions Integrated Safety Controller Solutions


Compact

GuardLogix

Safety Control System Options (Control Devices)

30

Fle

xibi

lity

and

Pric

e

Safety System Complexity / Functionality

MSR Relay

SmartGuard 600

GuardLogix

Armor

GuardLogix

CR30

GSR Relay

GSR & MSR Safety Relays

Cover most safety

functions

Modular expansion

Configurable

Guardmaster® CR30

• Software Configurable Safety Relay

• Supports up to 10 safety input circuits and up to 5 safety output zones

• 22 Safety I/O; expandable by up to 16 standard I/O

• One software supports Guardmaster CR30, Micro800®, PowerFlex®, and PanelView™ Component

SmartGuard™ 600

Dedicated safety controller with EtherNet/IP connectivity

16 safety inputs / 8 safety outputs / 4 std outputs

Networked safety I/O expansion (CIP Safety on DeviceNet)

Compact GuardLogix

High performance integrated safety

Standard , Safety, and Motion control

CIP Safety on EtherNet/IP

Superior ease-of-use for SIL2, SIL3, PLe safety functions

High Integrity AOIs GuardLogix

High performance integrated safety

Standard , Safety, and Motion control

CIP Safety on DeviceNet, ControlNet, Ethernet

Superior ease-of-use for SIL2, SIL3, PLe

safety functions

High Integrity AOIs

Armor GuardLogix

Full capabilities of GuardLogix

SIL3, PLe, CAT 4 safety control

IP67 wash-down protection

2 independent dual EtherNet/IP ports w/ DLR support

24VDC pass-through power


Safety Relay/Safety Controller/Safety PLC Selection Matrix

Safety Relays • 1 Zone • Local/Hardwired I/O • Simple Safety Logic • 1 to 2 dual channel Inputs • 2 to 3 outputs

Safety Controllers & Expandable / Configurable Relays • 1 to 3 Zones • Local & Distributed I/O • Simple & Semi-complex

Safety Logic • 1 to 10 dual channel Inputs • 1 to 10 outputs • Basic Diagnostics thru PLC

Safety PLCs • More Than 3 Zones • Distributed I/O • Simple & Complex Safety &

Standard Logic • 1 to 200 dual channel Inputs • 1 to 200 outputs • Advanced HMI Diagnostics


Agenda



Introduction

Market Segments





Rockwell Automation Service & Support! Assessments

Arc Flash Analysis

Hazard Risk LOTO HAZOP

Validation Safety circuit

analysis Machine stop time

services Conformance

audits Safety system

validation

Compliance Consulting CE conformance Functional safety

(ex. ISO 13849-1 and IEC 62061, ISO, ANSI, IEC, CE, OSHA, NFPA, CSA, AS )

200+ Safety Professionals Available Globally 100+ Machinery Safety Certified Resources 80+ Process Safety Resources Over 200 Training Courses for help customers develop competency

30 + RA Safety Professionals 3 RA Safety Partners – 20 Resources

4 Safety Professionals

20+ RA Safety Professionals 12 RA Safety Partners – 24+ Resources

20+ Safety Professionals




Training TUV Certification Risk Assessments Safety Standards Safety Products Arc Flash LOTO

Integration / Start Up

Circuit/logic design Installation Arc flash

remediation MCC Arc Flash

upgrades Project

Management

Remediation Solutions Complete

Turnkey Systems

The most complete suite of safety services in the industry!


Rockwell Automation has Safety Tools to Help

Customers be Compliant and Safe!

Safety Return-On-Investment Tool Find out how to quantify the savings and productivity gains from safety investments. The Rockwell Automation Safety Return-On-Investment Tool accounts for improved safety, reduced claims, improved productivity, and other issues unique to safety applications.

Safety Functions

Safety Functions Program The Safety Functions Program is building block approach to designing safety systems. Each building block has a complete documentation package that includes a description of each safety function, an electrical schematic, a bill of material, a SISTEMA verification calculation and a verification and validation plan.

SAB Safety Automation Builder The Safety Automation Builder software package that allows users to import images of their machines. Users can identify hazardous access points and the associated hazards in order to develop a list of safety products that will be used to mitigate the risk. This gives the customer a complete drawing, a bill of material and SISTEMA calculation.

Safety Accelerator

Toolkit

Safety Accelerator Toolkit This toolkit provides easy to use system design, programming, and diagnostic tools to assist you in the rapid development and deployment of your safety systems using GuardLogix, Compact GuardLogix, or SmartGuard 600 Controllers, Guard I/O, and Safety Devices. The toolkit includes a risk assessment and system design guide, hardware selection guide, CAD drawings, safety logic routines, and operator status and diagnostic faceplates.

Connected Components

BB

Connected Components Building Blocks These building blocks are tools that help customers develop safety solutions that utilize component class safety solutions. These building blocks include sample programs, electrical schematics and configuration document that help in the

ProSafe Builder

ProSafe Builder The ProSafe Builder software gives users the ability to layout complete trapped key solutions for machinery safety applications with a tool that generate a bill of material and system configuration schematic/map.

The broadest suite of safety tools in the industry!

http://safetyroi.avidcom.com/







We care what you think!

On the mobile app:

1. Locate session using

Schedule or Agenda Builder

2. Click on the thumbs up icon on

the lower right corner of the

session detail

3. Complete survey

4. Click the Submit Form button

35

Please take a couple minutes to complete a quick session survey to tell us how we’re doing.

2

3

4

1

Thank you!!


PUBLIC INFORMATION

Questions?


PUBLIC INFORMATION

Thank you for participating!

machinery safety system selection and development

Technology

safety actuators

safety products

best safety system

safety system components

relaybased safety systems

low complexity safety

safety output devices

simple safety relay