SAFETY STANDARDS & SOLUTIONS MATERIAL HANDLING & INTRALOGISTICS Renaat Mondelaers SICK Certified Functional Safety Application Expert CFSAE by SGS/TÜV Saar Mikaël Degent SICK Product Manager Industrial Safety Safety Expert MATERIAL HANDLING & INTRALOGISTICS ONCE THERE WAS AN APPLICATION SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 2 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 1
MATERIAL HANDLING & INTRALOGISTICS AND WITH AN APPLICATION COMES GREAT RESPONSIBILITIES The machine directive 2006/42/EC states: the manufacturer shall ensure that it satisfies the relevant essential health and safety requirements ry manufactured in conformity with a harmonised standard,, shall be presumed to comply with the essential health and safety requirements Useful standards: EN 619: Continuous handling equipment and systems Safety and EMC requirements for equipment for mechanical handling of unit loads EN 1525: Safety of industrial trucks Driverless trucks and their systems ISO 3691: Industrial trucks Safety requirements and verifications part: 1, 2, 3, 4 (draft),5 and 6 EN ISO 10218-2: Robots and robotic devices Safety requirements for industrial robot Part 2: robot systems and integration EN 415: Safety of packaging machines The manufacturer of machinery must ensure that a risk assessment is carried out, and The machine must be designed and constructed following the results of the risk assessment SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 3 RISK ASSESSMENT PROCESS EN ISO 12100 FIGURE 1 Determination of the limits of the machine Hazard Identification Risk Estimation Risk Assessment Risk Evaluation Are the risks reduced? yes Document & End no Risk reduction SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 4 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 2
MATERIAL HANDLING & INTRALOGISTICS IMPACT HAZARDS SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 5 MATERIAL HANDLING & INTRALOGISTICS CRUSHING HAZARDS SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 6 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 3
MATERIAL HANDLING & INTRALOGISTICS DRAWING-IN HAZARDS SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 7 MATERIAL HANDLING & INTRALOGISTICS SHEARING HAZARDS SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 8 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 4
RISK REDUCTION PROCESS EN ISO 12100 FIGURE 2 Risk Assessment RISK Protective measures by designer Step 1 Inherent safe design Avoid hazards Step 2 Safeguarding & Collective protective measures Step 3 Personal protective measures At machine (warning signs, signals,...) Instruction handbook Residual risk after protective measures, implemented by designer SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 9 MAXIMUM GAPS TO AVOID CRUSHING EN 619 - CLAUSE 5.1.1.1 In the working and traffic area danger zones between powered and fixed components [ ] shall be safeguarded. This shall be achieved by providing a continuous maximum gap of 5 mm between moving and fixed components SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 10 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 5
MINIMUM GAPS TO AVOID CRUSHING EN 349 - TABLE 1 Body Head Leg Foot a 500 mm a 300 mm a 180 mm a 120 mm Toes Arm Hand/wrist/fist Finger a 50 mm a 120 mm a 100 mm a 25 mm SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 11 MINIMUM GAPS TO AVOID CRUSHING IMPLEMENTED EN 619 - FIGURE D.10 Frame edge h Frame of carr + Wheel Ground h (mm) 120 100 Frame i 80 70 mm 60 40 Free space for feet 20 h 0 0 20 40 60 80 100 120 140 160 180 i i (mm) SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 12 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 6
MATERIAL HANDLING & INTRALOGISTICS INHERENT SAFE DESIGN GIVES LESS RISKS SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 13 RISK REDUCTION PROCESS EN ISO 12100 FIGURE 2 Risk Assessment RISK Protective measures by designer Step 1 Inherent safe design Step 2 Safeguarding & Collective protective measures Step 3 Personal protective measures At machine (warning signs, signals,...) Instruction handbook Residual risk after protective measures, implemented by designer Avoid hazards Safeguard against hazards SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 14 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 7
SAFEGUARD AGAINST HAZARDS EN 619 CLAUSE 5.1.4.6 The transport area of power driven transfer cars shall be separated by Fencing,at least 2,0m high Access doors, with interlocks to stop all dangerous movements when opened Where load entry/exit points may be misused to gain access to danger zone, measures need to be taken to prevent access Trip devices to detects persons entering the dangerous zone Detecting a difference between persons and material When necessary, extra protection on the transfer cars and interfacing conveyors is needed Trip devices to detect persons in the travelling path of the installation SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 15 SEPARATION OF THE DANGEROUS ZONE MECHANICAL FENCING Fixed mechanical guard Movable mechanical guard SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 16 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 8
DESIGN AND CONSTRUCTION OF GUARDS EN ISO 14120 CLAUSE 5.3 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 17 SAFETY DISTANCES TO PREVENT REACHABLE HAZARDS EN ISO 13857 CLAUSE 4 Fixed guard high risk! Reaching over low risk Clearance " Reaching through Reaching under Reference plane Hans Georg Brühl GmbH SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 18 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 9
MOVABLE MECHANICAL GUARDS - INTERLOCKING EN ISO 14119 CLAUSE 4 Without interlocking Interlocking guard Interlocking guard with guard locking Low risks Doesn t generate a safe stop Safeguarding against ejecting pieces High risks Generates a safe stop High risks Generates a safe stop and safe locking Can be used for process safety SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 19 INTERLOCKING TYPE SELECTION EN ISO 14119 CLAUSE 6.2 Total stop time of the machine time to reach hazard? No Yes Interlocking with guard locking Interlocking without guard locking possible TR10 Lock STR1 switch SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 20 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 10
PREVENT ACCESS TO DANGEROUS ZONE SAFETY LIGHT CURTAINS Light curtain vertical SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 21 CALCULATION OF THE RIGHT SAFETY DISTANCE EN ISO 13855 CLAUSE 6 Approach speed S 500 mm S > 500 mm K = 2.000 mm/s K = 1600 mm/s Stop time of the installation Response time sensor + Cycle time logic + + Response time output + Stop time movement Reach over distance ( Cro) S = K x T + C Reach through distance ( Crt) SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 22 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 11
DIFFERENCE BETWEEN PERSONS AND MATERIAL EN 62046 - SCOPE Practical solutions for applications with: Electro Sensitive Protective Equipment (ESPE) IEC 61496 1 t/m 4 Pressure sensitive mats and floors ISO 13856-1 Talks about: Safety characteristics of ESPE s and pressure mats and floors PSDI (for press applications) Blanking Start restart interlock Muting EDM Inspections SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 23 DIFFERENCE BETWEEN PERSONS AND MATERIAL EN 62046 - CLAUSE 6.1.3.3 Blanking Optional function that permits an object of a size greater than the detection capability of the ESPE to be located within the detection zone without causing an OFF-state of the OSSDs Important: I can not be possible to reach the danger through the blanked zone of the light curtain! SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 24 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 12
DIFFERENCE BETWEEN PERSONSAND MATERIAL EN 62046 - CLAUSE 5.7 Muting Temporary suspension of a safety function Automatic activation by the safety related parts of the control system Can be used to allow access by persons or by materials; During a non-hazardous portion of the machine cycle, or When safety is maintained by other means SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 25 MUTING REQUIREMENTS EN 62046 - CLAUSE 5.7 The muting has to start automatically. Manual activationnot is allowed A muting sequence exists of minimal 2 different signals, which are independent of each other. A muting sequence cannot be depended of only: 1 electrical signal, or 1 software signal An incorrect sequence of muting signals can not activate the muting function. An error in the sequence during muting has to cause a safe stop. M4000 advanced + UE403 The muting has to end as soon at the material is passed SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 26 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 13
MUTING SIGNAL REQUIREMENTS EN 62046 - ANNEX D Ensure that muting cannot be unintentionally triggered by a person Use a right position for the sensors Use sequence control functions and timer functions SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 27 MUTING SIGNAL REQUIREMENTS EVALUATE NEW RISKS Take necessary actions to prevent Access to the dangerous zone by walking next to material when the muting is active. Crushing danger between the moving material and the fixed parts of the installation SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 28 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 14
DETECTION OF PERSONS IN THE TRAVELLING PATH SAFETY LASER SCANNERS Muting sensors Safety laserscanner SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 29 DETECTION OF PERSONS IN THE TRAVELLING PATH EN 1525 CLAUSE 5.9.5 a c When using ESPE s on a vehicle: a) They shall operate at least over the full width of the truck b) They shall detect persons in the full path of the vehicle, taken into account possible turns and movements of the vehicle c) The vehicle s traveling speed is used to determine the minimum safety distance d) Safety supplements may be necessary dependent on the application and the technology used b S3000 scanner SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 30 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 15
DETECTION OF PERSONS IN THE TRAVELLING PATH EVALUATING NEW RISKS Make sure everybody close to the vehicle is detected Take necessary actions to prevent Scissor-effect S3000 scanner SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 31 RISK REDUCTION PROCESS EN ISO 12100 FIGURE 2 Risk Assessment RISK Protective measures by designer Step 1 Inherent safe design Step 2 Safeguarding & Collective protective measures Step 3 Personal protective measures At machine (warning signs, signals,...) Instruction handbook Designer input to User Residual risk after protective measures, implemented by designer Avoid hazards Safeguard against hazards Warn against hazards SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 32 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 16
INFORMATION FOR USE EN ISO 12100 CLAUSE 6.4 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 33 MATERIAL HANDLING & INTRALOGISTICS SUMMARY Risk Residual risk Risk assessment Inherent safe design Collective protective measures Personal protective measures Bad implementation t = Reason for manipulation SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 34 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 17
MATERIAL HANDLING & INTRALOGISTICS DIFFERENCE BETWEEN OPERATOR AND MATERIAL SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 35 DIFFERENCE BETWEEN MAN AND MATERIAL MUTING PRINCIPLES 2 SENSORS CROSS MUTING 4 SENSORS PARALLEL MUTING 2 SENSORS EXIT ONLY MUTING SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 36 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 18
2 SENSORS CROSS MUTING EN 62046 - ANNEX D Advantages: Only 2 sensors needed Bi-directional muting Continues muting possible Disadvantages: Precise alignment needed Only for homogeneous and centralized load ATTENTION! SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 37 4 SENSORS PARALLEL MUTING EN 62046 - ANNEX D Advantages: Bi-directional muting Can be used as unidirectional muting More flexible for different types and dimensions of load Easy alignment of muting sensors Disadvantages: More sensors needed All muting sensors need to be cleared before the next muting cycle can start = more space needed (S2) SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 38 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 19
2 SENSORS EXIT ONLY MUTING EN 62046 - ANNEX D Advantages: Only 2 sensors needed Easy alignment of muting sensors More flexible for different types and dimensions of load Disadvantages: Only exit applications = unidirectional muting Light curtain needs to be cleared within 4s when 1 muting sensor is cleared SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 39 MUTING HARDWARE CONCEPT Integrated into safety light curtain M4000 + UE403 Integrated into safety controller or muting module Flexi Soft SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 40 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 20
MUTING MUTING SENSORS Tactile sensors (position switches) Ultrasonic sensors Inductive proximity sensors Magnetic proximity sensors Capacitive proximity sensors Through-beam photoelectric sensors Photoelectric retro-reflective sensors Photoelectric proximity sensors Distance sensors Identification sensors (barcode, RFID, ) Inductive loops Signals from the safety-oriented controller SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 41 MATERIAL HANDLING & INTRALOGISTICS SAS FUNCTION Detection = STOP ZONE 1 è LC4 ACTIF LC 1 to 3 ZONE 1 ZONE 2 ZONE 1 & 2 SAFETY OK è LC4 in Muting LC 4 Door 2 Open = STOP ZONE 2 è LC4 ACTIF Door 1 Open = STOP ZONE 1 è LC4 ACTIF SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 42 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 21
ALTERNATIVE SOLUTIONS SAFE ENTRY/EXIT SOLUTION Intelligent horizontal safety light curtain C4000 Fusion SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 43 MATERIAL HANDLING & INTRALOGISTICS SAFE ENTRY/EXIT SOLUTION Light curtain horizontal SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 44 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 22
MUTING ATTENTION! CRUSHING HAZARDS è EN 349 - TABLE 1 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 45 ALTERNATIVE SOLUTIONS MUTING WITH SAFETY LASER SCANNERS SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 46 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 23
St ör u n g Si c Qh er ui th t i ei er t u n g Si S c t h a er r h t ei t St ör u n g Si c Qh ui er th t i er ei ut n g Si c S h t er a h r t ei t ALTERNATIVE SOLUTIONS SAFE PORTAL SOLUTION The PLC evaluates the input received and monitors the relevant cut off path (protective field) No programming of case switching Faster reaction time Adaptable to more different forms/vehicles SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 47 ALTERNATIVE SOLUTIONS SAFE PORTAL SOLUTION S3000 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 48 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 24
ALTERNATIVE SOLUTIONS ENTRY/EXIT SOLUTION è AGV GATE WITH RFID ü The muting request may be initiated by a correct RFID tag read ü Highly flexible system with Flexi Soft in combination with all SICK type 4 ESPE s and RFID Reader ü Example Software ü TÜV Certification (EC type examination) ü Up-to PL e (min. PL d) Do you need a special solution? Contact us SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 49 MATERIAL HANDLING & INTRALOGISTICS FENCELESS aka LESS FENCE SAFETY CONCEPT SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 50 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 25
MATERIAL HANDLING & INTRALOGISTICS FENCELESS aka LESS FENCE SAFETY CONCEPT SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 51 MATERIAL HANDLING & INTRALOGISTICS TRANSFER CAR ü ü ü ü Safe deceleration / ramp down monitor Warning zone Safe Stop - Safe detection of a person in the dangerous area Safe speed monitoring Safe position monitoring SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 52 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 26
TRANSFER CAR LAYOUT Optical data transmission Vehicle controller IOIOIOIOIOI OIOIOIOIOI Control & diagnostic communication Signal 1 & 2 Distance sensor Safety & diagnostic communication STO Signal 1 Position & speed information Mechanical Brake Signal 2 Position & speed information Splitter box MF SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 53 MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Safety laser scanner Warning field Safety laser scanner Protective field microscan 3 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 54 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 27
MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Safe standstill monitoring SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 55 MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Safe speed monitor Safe direction monitor SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 56 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 28
MATERIAL HANDLING & INTRALOGISTICS SAFE DIRECTION & SAFE SPEED MONITOR 5 4 3 2 1 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 57 MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Safe speed monitor Safe direction monitor SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 58 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 29
MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Safe speed monitor Safe direction monitor SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 59 MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Safe speed monitor Safe direction monitor SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 60 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 30
MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Safe speed monitor Safe direction monitor SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 61 MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Safe standstill monitoring SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 62 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 31
MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Obstruction in the traveling path of the safety laser scanners SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 63 MATERIAL HANDLING & INTRALOGISTICS SAFE CAM MONITORING (RELATION BETWEEN POSITION AND SPEED) SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 64 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 32
MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Safe speed monitor Safe direction monitor Safe position monitor SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 65 MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Safe speed monitor Safe direction monitor Safe position monitor SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 66 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 33
MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Safe speed monitor Safe direction monitor Safe position monitor SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 67 MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Safe speed monitor Safe direction monitor Safe position monitor SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 68 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 34
MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Safe speed monitor Safe direction monitor Safe position monitor SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 69 MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Safe speed monitor Safe direction monitor Safe position monitor SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 70 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 35
MATERIAL HANDLING & INTRALOGISTICS SAFE MOTION FUNCTIONS + SAFETY LASER SCANNERS Safe speed monitor Safe direction monitor Safe position monitor SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 71 SAFETY IN MOBILE APPLICATIONS INTERACTION BETWEEN SAFE MOTION AND SAFETY LASER SCANNERS SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 72 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 36
MATERIAL HANDLING & INTRALOGISTICS SUMMARY CONVEYORS & TRANSFER CARS Risk assessment Safety concept THINK OUTSIDE THE BOX SAS function SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 73 SICK Safety Seminar Safety standards and solutions Material handling & intralogistics 37