ROSS Controls

Modern Safety Systems and Advanced Fluid Power Solutions

Chris BrogliGlobal VP of Safety Business Development

ROSS ControlsTUV FS Expert ID#213/13Phone: 1-859-595-9630

Email: chris.Brogli@rosscontrols.com

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Today we live in a “Global Environment”. Competition is everywhere.

This competition is driving technology advancement across the globe.

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Technology is changing in every technology segment.

1900-2000 Gasoline only Early 2000’s Hybrid 2010’s Electric Today Self-driving

Early 1900’s-1990’sWired

1990’s Bag Early 2000’s Flip Mid 2000’sSmart

Today Apple Watch

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Machines are evolving with new technologies that require advanced functionality.

Safety Technology is evolving in a similar manner

Safety Technology Advancements• Fixed Guarding• Moveable Guarding• Safety Interlocks• Presence Sensing Devices• Collaborative Systems

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19

70

’s &

ea

rly

80

’s

• Discrete Safety

• Standard PLC’s

• Basic Safety Relays

• HMI’s

• Electronic Safety Switches

• Light curtains

• 2 channel safety circuits

• Standard Products

• Standard PLC’s

• Basic Relays

• Panel lights

• Pushbuttons

• Basic Safety Switches

• Basic Safety Circuits

Let’s take a look at how these advancements are affecting electrical safety solutions!

• Semi-integrated Safety

• Safety Controllers

• Safety PLC’s

• Safety Servo’s & VFD’s

• Safety Valves

• Electronic Presense

Detection

• Advanced safety circuits

Machine safety is evolving with new technologies that improve safety and productivity.

• Integrated Safety

• Advanced safety &

security control systems

• Collaborative robots

• Personnel ID systems

• Adaptive machine

functions

• Self configuring systemsLate

19

80

’s &

19

90

’s

20

00

’s

To

da

y

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Safety & Control Solutions of the past

Physically Independent

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Safety and Control Solutions of today

Physically Combined

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In 2009 safety relays were 70% of the safety logic today 70% or the market is safety controllers & safety PLC’s. This allows for better control & monitoring of the safety system.

30%

70% 30%

70%

Relays

Controllers & PLC’s

Relays

Controllers & PLC’s

The main reason that safety systems are advancing is because technology is advancing.

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19

70

’s &

ea

rly

80

’s

• Use of basic safety

relays to turn off

standard solenoids.

• Use of blocked & open

center solenoids

• Use of lockable ball

valves

• Turning off power

with standard

controls was good

enough.

• Use of standard

solenoids (SR)

• Use of standard

ball valves

• Use of safety relays,

safety controllers &

safety PLC’s

• Use of redundant

safety solenoids

• Use of dedicated LOTO

valves

Fluid power solutions are evolving the same way electrical products did 10 to 15 years ago.

Late

19

80

’s &

19

90

’s

20

00

’s

To

da

y

Fluid Power Safety Solutions are evolving too!

• Use of advanced safety

control systems

• Use of multi-function

fluid power safety

solutions

• Use of modular LOTO

systems

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Our older products were self monitored but were large and expensive. Our new products are smaller and match the electrical safety transition.

Old Products with Internal Monitoring

Contemporary Products with External Monitoring

Current Products with Electrical Internal Monitoring

Pneumatic safety solutions are evolving with solutions that make them easier to integrate.

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ISO 13849-1 – 2015 required users to include fluid power safety as part of the safety control system.

Most companies ignored fluid power safety until the ISO13849 standard

changed in 2015.

The reason that that fluid power safety was not addressed until later than electrical safety is because the standards didn’t include it.

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Let’s take a look at standards of today to understand the requirements.

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OSHA Machine Safety 1910.xxx

Machine Safety - General Safety RequirementsANSI B11.0

Machine Safety - Principles for Risk AssessmentANSI/RIA TR15.306

Machine Safety - Selection of Programmable Electronic Systems (PES/PLC) for Machine Tools

ANSI B11.19

Electrical equipment of machinesANSI/NFPA 79

European Machine Directive 2006/42/EC

Machine Safety - Basic concepts EN/ISO 12100

Machine Safety - Principles for Risk AssessmentEN/ISO 14121

Machine Safety - safety-related parts of control

systemsEN/ISO 13849-1

Pneumatic Safety – EN/ISO 4414Hydraulic Safety – EN/ISO 4413

Machine Safety -Functional safety of

EEPES control systemsIEC 62061

Pneumatic Safety – ANSI B11.0Hydraulic Safety – ANSI B11.0

Machine Safety - Electrical equipment of machines IEC 60204-1

Notice that there are specific standard for Fluid Power Safety.

General Safety Requirements

Risk Assessment Requirements

Design Requirements

Fluid Power Requirements

Electrical Requirements

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ISO12100 & ANSIB11.0 outline the basic requirements for risk assessment & risk reduction.

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Risk Assessment

The top part of ISO12100 and ANSI B11.0 deal with assessing risk.

The ISO12100 and ANSIB11.0 methodologies provide a

systematic approach as shown in the flow chart below.

Determine the Limits

Identify the Hazards

Estimate the Risk

Evaluate the Risk

Assessment

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There are specific requirements for the use, implementation and utilization of hydraulic and pneumatic components in control systems according to ISO13849-1.

ISO4414 & ISO4413 say that hydraulics & pneumatics must be considered and identified risk must be eliminated or reduced.

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We need to think about powered and unpowered hazards, like falling loads!

This means that we need to think about…

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There are a number of risk estimation methods that yield varying results. ISO13849 has become one of the most widely used methodologies.

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TR13.306 Methodology

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The reason that many companies have adopted ISO13849 is because it addresses all technologies and provides a more holistic approach to machine safety.

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EN 954-1 EN ISO 13849-1

Electrical Control Circuits Control circuits all technologies :• Electrical• Pneumatic• Fluids• Hydraulic

Safety Categories B, 1, 2, 3 & 4 Performance Levels PLa to PLe

Safety provided by the structure of the control circuit

Safety provided by:• The architecture/structure (EN954-1

categories)• The reliability of the system (MTTFd, B10d)• The diagnostic coverage of the system (DC)• The preventive measures against common

causes of failure (CCF)

Draw a diagram (schematic) Draw a diagram and verification of PLDoes PL(achieved) = PLr (required) ?

Not just electrical

anymore!

EN954-1 was withdrawn in

2011. The only place that

Categories exist today is

as a part of ISO13849.

ISO13849 adds some important

factors that must be considered in

the selection design and

implementation of safety solutions

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If a machine safety solution is required it must be designed to meet a standard to prove compliance to the machinery directive.

Since EN954-1 was withdrawn in December of 2011 and IEC62061 only deals with

electrical, electronic and programmable electronic systems. ISO13849-1 has become the

most commonly used machine safety standard because it addresses all technologies

including fluid power.

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If fluid power hazards are moderate, serious or catastrophic the safety solution has to meet PLc, PLd or PLe.

ANSI B11.0 & EN13736 provide performance requirements based on pressure & force.

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Once we are done with the assessment we need to determine how to reduce risk. This should include fluid power risk as well.

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The bottom part of ISO12100 and ANSI B11.0 deal with risk reduction.

Reduction by Design

Reduction by Guarding

Reduction by Safeguards

Reduction by Information & PPE

Risk Reduction

Reduction by Elimination

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Let’s look at the list of Safety Functions from ISO13849-1.

The ones circled in red apply to fluid power safety as well. The following slides will show how these are used in modern

safety solutions.

Elimination

Safeguard

Safeguard

Safeguard

Parameterized SafeguardsSafeguard

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Pneumatic Safety Devices & Solutions

● LOTO valves for control of hazardous energy

● Safety Exhaust/Safe Bleed valves for release of hazardous energy

● Safe Return/Safe Direction valve for safe control of actuators

● Safe Stop/Safe Load holding for safe stopping of actuators

● Some additional ones to mention:

● Safe speed control

● Safe pressure control

Common fluid power safety solutions.

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Elimination

LOTO is used for maintenance, repairs and servicing of machinery.

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• Valve should be well marked

• Distinct from other manual valves

• Valve should be differentiated by its appearance

• Full diameter exhaust (rapid release of stored energy)

• Should only be able to be locked only in off position

• “Positive action” which would indicate only two positions (ON and OFF)

• A method for the employee to verify that the energy has dissipated after initiating lock out process.

Pneumatic LOTO Best Practices

The LOTO/energy isolation device is not an E-Stop device, but it may serve as the primary isolation device in an emergency.

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• Valve should be well marked

• Distinct from other manual valves

• Valve should be differentiated by its appearance

• Should only be able to be locked only in off position

• “Positive action” which would indicate only two positions (ON and OFF)

• A method for the employee to verify that the energy has dissipated after initiating lock out process.

Hydraulic LOTO Best Practices

Hydraulic LOTO/energy isolation is similar to pneumatic LOTO but you can’t exhaust hydraulic fluid to atmosphere. You bleed it back to tank.

Positive OFF

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Safety Input Devices

Safety Logic Devices

Safety Output Devices

• Door Switches• Emergency stops• Light curtains• Pull-cords• Area scanners• Safety mats• Safety cameras

• Safety Relays• Safety Controllers• Safety PLC’s

• Safety Contactors• Safety VFD’s• Safety Servos• Safety Valves

Complete Safety Function++ =

When we do a risk and identify the risk level we need to design our safety solution to meet the Required Performance Level.

Safeguard

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Guarding Considerations

• Can you reach over, under or around the guard?

• Is the guard attached with hardware that requires a tool for removal?

• Is the guard a moveable guard?

• Is it interlocked?

• Can someone get to the hazard before it can come to a stop?

• Is the guard and interlock robust enough for the application?

• Is the interlock rated for the environment that it will operate in?

• Is the interlock safety rated?

• Can the interlock be bypassed?

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Safe Isolation

You have to be very careful with safe isolation solutions because they remove air or hydraulic energy. This could cause cylinders to

shift/move (Especially in vertical applications).

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Safe Direction is a common safety related function/parameter that is used with drives and servos. We can accomplish that today by the use of Safe-return valves.

Safe Direction/Safe Return

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Safe Stop/Safe Holding

Safe Stop is a common safety related function/paramets that is used with drives and servos. We can accomplish that today by the use of Safe-load-holding valves.

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Let’s look at the key differences between standard and safety products so that we can discuss advanced fluid power safety devices.

X

X

Ball valves are not tamper resistant and can be locked in the on, off and in-between positions and they do not have local indication that energy has been dissipated. They are also not easily identifiable.

A single failure of a standard single-acting solenoid can lead to the loss of the safety function and these valves do not have sensing to detect when a failure occurs.

A single failure of a standard double-acting solenoid can lead to the loss of the safety function and these valves do not have sensing to detect when a failure occurs.

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Example – Winder unloading table

Extend

Retract

24

35

1

Broken spring = Unable to obtain center positionDe-energized valve caused table to extend

If using the retract button, the safety mat would cause the table to extend

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Example – Valve sticking

Transfer press line part removal Operator removes part from conveyor A

Part is placed on rack C

Fork trucks remove full racks, load empty racks

Crushing/Shearing Hazard

Motionless

2

3 1

Rotating

2

3 1

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So let’s spend a few minutes to talk about what is next in fluid power safety

• Connected & integrated fluid power safety solutions• EtherNet Connected Devices

• I/O Link Connected Devices

• Collaborative Applications• Safe speed solutions

• Safe pressure solutions

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Sm

all

Machin

es • Connected Systems

• Easier to Apply

• Faster wiring

• Easy trouble-shooting

• Diagnostics at the relay and

at I/O device (LED’s)

• Easier to modify (QD’s)

• Hardwired Systems

• Cumbersome

• Difficult to Apply

• Time consuming wiring

• Difficult to Trouble-shoot

• Easily Bypassed

• Hard to modify (Rewire)

Connectivity has changed and will continue to change over the next 3 to 5 years.

• Networked Systems

• Flexible

• Easy to Apply

• Easy to trouble-shoot

• Enhanced diagnostics

• Easiest to modify

(Program change)

Machine safety connectivity is evolving with new technologies that improve reliability and facilitate continuous improvement thru enhanced diagnostics and improved flexibility.

Workcell

s&

Sm

all

Lin

es

Conti

nuous L

ines

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Today this is accomplished by hardwired & quick disconnect systems.

In the future we will see valves that are connected via safety networks with no hard-wired connections.

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To support the evolving market automation & fluid power suppliers are moving from hardwired to smart & connected solutions !

The result is smart and connected solutions that reduce wiring time and enhance diagnostics and improve reliability.

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I/O Link and EtherNet based Safety are 2 protocols that are being tested.

Both solutions would use quick disconnects,

LED’s and smart monitoring to provide system

status and system health feedback.

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Primary Justifications for Integrated Safety Solutions

• Wiring & installation cost reductions• Simplified connectivity which reduces errors• Single connectivity methodology across the line• Enhanced line diagnostics for faster troubleshooting• Improved validation capabilities

These integrated solutions of for small and large lines and workcells that are made up of multiple stations.

These machine utilize modular zone control and a combination of risk reduction techniques that include fluid-

power safety, motion and servo safety utilizing a varieity of safety input devices.

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Let’s break this down to the cell/station level and look at wiring costs.

• Hard Wiring Times

• 2 Door switches – 8 to 12 Wires

• 2 Safety Valves – 6 to 8 wires

• 2 to 5 drives – 30 to 50 wires

• Industry average 15 minutes per wire

@ $35 per hour = $1300 per station

• Modular Wiring Times

• QD block wiring – 1 to 2 hours per

I/O block

• QD connection from block to device

– 25 point @ 5 minutes

• 6 hours @ $35 per hour = $210 per

station

• Smart & Connected Wiring Times

• EtherNet & Power QD connections

@ 5 minutes

• 10 connections

• 1 hour @ $35 per hour = $35 per

station

• Impact Analysis

• 16 stations

• Hardwired $20,800

• Connected $3,260

• Integrated $560

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Collaborative Applications are now being used.

Common Solutions Include:• Safe Limited Speed• Safe Limited Torque• Safe Pressure• Safe Position• Safe Direction

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Let’s look at how companies are doing safe-speed and safe-pressure in Collaborative Applications today.

• Collaborative Machine Solutions• Safe Speed• Safe Torque• Safe Pressure• Safe Position• Safe Direction

Weld Station

Rivet Station

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Best in class companies are using these advanced technologies to improve safety and productivity.

The Aberdeen study showed that the safest companies are also the most productive!

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The automation industry is changing with technologies that improve safety and productivity.

Things to consider:• Are you taking advantage of these technologies?

• Is there more that you can do?

• Does your current infrastructure enable the use of new technologies?

• What does 1% of productivity mean to you and your company?

• Best in class companies see 4 to 5% better performance than others in their industry!

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Closing Comments

• Fluid Power Safety is Important

• The Standards require us to address Fluid Power Safety

• Fluid Power needs to be part of the risk assessment– Based on ANSI B11.0 2015 requirements and ISO4413 and ISO4414

• Fluid Power components are part of the SRP/CS– Safety Related Parts of the Control System according to ISO13849-1

• We can’t ignore Fluid Power anymore!