taktik(z) | Leuze electronic | Safety Training

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Mark Smokowicz / LAS Safety Training Mark Smokowicz Leuze electronic Product Management & Safety Products PM

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taktik(z) | Leuze electronic | Safety Training

Transcript of taktik(z) | Leuze electronic | Safety Training

Page 1: taktik(z) | Leuze electronic | Safety Training

Mark Smokowicz / LAS

Safety Training

Mark Smokowicz

Leuze electronic

Product Management & Safety Products PM

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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

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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

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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

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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

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“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

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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.

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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

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Resolution of AOPD

Resolution (d) = pitch (p) + lens diameter (Ø)

d = p + ØChannel

p Ø

Channel

Resolution (d) AKA Object Sensitivity (Os)

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Dpf, Depth Penetration Factorbased on ANS-RIA

Light Curtain

Light Grid

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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

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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

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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

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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

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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 ?

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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

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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”

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Stopping distance examples

14.8

18.5

18

0 5 10 15 20

EN999

ANSI-RIA

OSHA

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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.

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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

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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

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Web based tools

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Calculation wizards

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Introduction to Risk Assessment

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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

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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

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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

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Risk elements

• slight• severe

severity of the injury

• rarely, short • frequent, long

exposure in danger area

• possible• rarely possible

possibility of avoidance

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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

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Risk reduction indexCSA Z434-03

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Safeguard selection matrixCSA Z434-03

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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

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Types of AOPD applications

Making a danger point safe

Access guarding

Safeguarding an area

Perimeter guarding

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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

Page 36: taktik(z) | Leuze electronic | Safety Training

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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

Page 37: taktik(z) | Leuze electronic | Safety Training

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Thank You for Your Interest in Safety Products of

Leuze electronic