practical application of en iso 13849-1 for machine tools - eberhard beck
TRANSCRIPT
“Safety related control systemsfor machinery“
ST/Beck -1-09.09.10
Brussels, 9th September 2010
“Practical application of EN ISO 13849-1
for machine tools”
INDEX Werke GmbH & Co. KG Hahn & Tessky
Eberhard Beck Head of control techniques INDEX-Werke
EU-Symposium
“Safety related control systems for machinery”
“Safety related control systemsfor machinery“
ST/Beck -2-09.09.10
0 General Introduction The company of INDEX
1 Practical application of Workpiece clamping device
EN 13849 to Machine Tool as EN 13849 safety function
Requirements according
EN 12415 // EN ISO 23125
Requirements applying
EN ISO 13849 risk analysis
Conclusion
2 Further experiences out of Translation problems “How
the EN ISO 13849 application to get EN ISO 13849 diagrams”?
Multiple safety functions for
EN ISO 13849 requirements
3 Summary out of the EN ISO 13849
application
Overview
Structure for the Presentation
“Safety related control systemsfor machinery“
ST/Beck -3-09.09.10
1914 19541914 1970
First NC machineFounded by
Hermann Hahn
Begin with the production
of turret screw machines
20.000 INDEX machines sold
1997Merger with
TRAUB-Drehmaschinen
GmbH
1992
Introduction of the modular
building block system with
the RatioLine and VerticalLine
1985First CNC-controlled multi
spindle machine with
hollow shaft motor
The Eugen und Irmgard
Hahn foundation becomes
shareholder with 85% after
the death of Eugen Hahn
1990
History of INDEX-WerkeFrom the beginning …
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Introduction of flexible
high performance
turn mill centers
2000 2002
Integration of various
technologies in serial
production
First provider of a
Virtual Machine
for the PC
2005 2009
Introduction of 5-axis-
turn mill centers of the
newest generation
History of INDEX-Werke… to the past 10 years
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Medical Industry
Fittings / Fluidics
Electronics
Automotive
Optics / Precision Mechanics
Air- / Spacecraft Technology
Customer segments and industries… typical cycle times and part numbers
Cycle times
from ≥ 1 second
up to > 2,5 hours
typical 30 to 240 s
Number of parts
from single part
production up to
> 10 Mio parts/year
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Locations and subsidiaries Agents
Turnover (2008) 510 Mio €
Number of Employees (2008) ca. 1950
Number of Machines (2008) ca. 1200
Export rate ca. 40 %
INDEX-Werke GmbH & Co. KG… in figures, locations and subsidiaries
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Typical parts machined by INDEX machine tools(examples for bar machining)
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Working zone of INDEX machines(example)
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Machining inside INDEX machines(video example)
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ST/Beck -10-09.09.10
0 General Introduction The company of INDEX
1 Practical application of Workpiece clamping device
EN 13849 to Machine Tool as EN 13849 safety function
Requirements according
EN 12415 // EN ISO 23125
Requirements applying
EN ISO 13849 risk analysis
Conclusion
2 Further experiences out of Translation problems “How
the EN ISO 13849 application to get EN ISO 13849 diagrams”?
Multiple safety functions for
EN ISO 13849 requirements
3 Summary out of the EN ISO 13849
application
Overview
Structure for the Presentation
“Safety related control systemsfor machinery“
ST/Beck -11-09.09.10
Workpiece clamping device as safety function(based on EN ISO 23125 + EN ISO 13849 requirements )
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P
Monitoring pres-sure cylinder A
Monitoring hydraulic pressure
Pressure cylinder A
Pressure cylinder B
Cylinder stop
Enabling cylinder movement
Main spindle with chuck
Sensor for jaw position
Clamping/ unclamping valves
A
B
nonreturn valves
Hydraulic power supply
Sensors for clamping pressure
Hydraulic pipes
PLC control + PLC software
24V/I
24V/O
24V/O
24V/O
24V/O
Monitoring pres-sure cylinder B
Monitoring jaw position
Workpiece clamping safety function“state of the art”
safety equipment (sensors) are monitored by PLC
“Safety related control systemsfor machinery“
ST/Beck -13-09.09.10
0 General Introduction The company of INDEX
1 Practical application of Workpiece clamping device
EN 13849 to Machine Tool as EN 13849 safety function
Requirements according
EN 12415 // EN ISO 23125
Requirements applying
EN ISO 13849 risk analysis
Conclusion
2 Further experiences out of Translation problems “How
the EN ISO 13849 application to get EN ISO 13849 diagrams”?
Multiple safety functions for
EN ISO 13849 requirements
3 Summary out of the EN ISO 13849
application
Overview
Structure for the Presentation
“Safety related control systemsfor machinery“
ST/Beck -14-09.09.10
EN 12415
Cat. “1”
EN954-1
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Meldepflichtige Unfälle an Werkzeugmaschinen
20000
25000
30000
35000
40000
45000
50000
1992 1994 1996 1998 2000 2002 2004 2006 2008
Jahr
An
zah
l
Maschinenrichtlinie (und Typ C Normen)
Improvement of accidents
in Germany since 1993
“C-Standards” for machine tools
in relation to “accidents at machine tools”
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EN 23125
PL “b”
EN13849
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EN ISO 23125 workpiece clamping function“state of the art”
EN ISO 13849 safety calculation
safety function “workpiece clamping”
evaluation according to DIN EN ISO 13849:2007
Institute of employers„ liability
insurance association (BGIA)
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VDW-Project
Functional safety for machine tools
More than 100 experts: 60 designers, 30 suppliers, 16 Safety Experts, …have
- 20 typical safety functions for machine tools defined
- 10 safety functions have been calculated in more than 1,5 years
- over 40 meetings have been hold and more than 200.000 € have been spent
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Definition of safety functionsworkpiece clamping device
“state of the art”
Standstill of the spindle
Clamping of the workpiece
Run up of the spindle
Diagnosis clamping state and door
Diagnosis clamping pressure and position
Machining of the workpiece
Run down of the spindle
Opening of the clamping device
Clamping
at
Clamping
at
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Definition of safety functionsworkpiece clamping device
“state of the art”
safely limited speed
workpiece clamping
without speed (= 0)
Monitoring work-
piece clamping with
speed (> 0)
safety function
b
b
d
SF2
SF3
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SISTEMA
PL “b”
EN23125
SISTEMA
PL “c”
EN23125
EN ISO 23125
EN ISO 23125
Safety block diagram + SISTEMA “PL result”workpiece clamping safety function
“state of the art”
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ST/Beck -23-09.09.10
0 General Introduction The company of INDEX
1 Practical application of Workpiece clamping device
EN 13849 to Machine Tool as EN 13849 safety function
Requirements according
EN 12415 // EN ISO 23125
Requirements applying
EN ISO 13849 risk analysis
Conclusion
2 Further experiences out of Translation problems “How
the EN ISO 13849 application to get EN ISO 13849 diagrams”?
Multiple safety functions for
EN ISO 13849 requirements
3 Summary out of the EN ISO 13849
application
Overview
Structure for the Presentation
“Safety related control systemsfor machinery“
ST/Beck -24-09.09.10
Figure A.1 – risk graph to define the performance level for each safety function
Selection of performance levels, a - e
PLrequired
PL “d”
EN13849
?
EN ISO 13849 result / requirementsworkpiece clamping safety function
“new safety status?”
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EN ISO 13849 requirements Comparison workpiece clamping safety functionagainst remaining residual risks in practice
In spite of PLr (EN 13849) “d” – in practice there is no
significant increasing of real safety at the machine
Because the following remaining residual risks in practice
also have to be considered:
- The risk of a collision between moving tools, tool carriers
and the workpiece or the workpiece clamping device
- The risk for a lack of clamping force based on a bad
maintenance condition of the clamping devices
- The risk of an insufficient hydraulic clamping
pressure in relation to the machining operations
- The risk for a not suitable maximum spindle speedfor the clamping device and / or the workpiece
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Without having PLr based on experts experience out of
“Type C” standard, the found high end PLr” of EN 13849
can be misleading
EN ISO 13849 requirements Evaluation EN ISO 13849 requirements against experts experience in practice
- The safety status only can be seemingly increased.
In practice, seldom a real safety improvement at the
real machine can be achieved
- The “high end PLr” requires high efforts in realization.
Remaining risks outside the scope of the safety related
control system could stay unnoticed
- The “high end PLr” often is very difficult to realize.
This can cause to further problems in operation of the machine and lead to the manipulation of safety devices
“Safety related control systemsfor machinery“
ST/Beck -27-09.09.10
0 General Introduction The company of INDEX
1 Practical application of Workpiece clamping device
EN 13849 to Machine Tool as EN 13849 safety function
Requirements according
EN 12415 // EN ISO 23125
Requirements applying
EN ISO 13849 risk analysis
Conclusion
2 Further experiences out of Translation problems “How
the EN ISO 13849 application to get EN ISO 13849 diagrams”?
Multiple safety functions for
EN ISO 13849 requirements
3 Summary out of the EN ISO 13849
application
Overview
Structure for the Presentation
“Safety related control systemsfor machinery“
ST/Beck -28-09.09.10
The big differences between new EN ISO 13849 PLr
safety requirements and EN 954-1 safety categories
based on “type C” safety standards leads to great
trouble and uncertainty among the applicants of the
EN ISO 13849 standard
Conclusion:
Conclusion
“Safety related control systemsfor machinery“
ST/Beck -29-09.09.10
Overview
Structure for the Presentation
0 General Introduction The company of INDEX
1 Practical application of Workpiece clamping device
EN 13849 to Machine Tool as EN 13849 safety function
Requirements according
EN 12415 // EN ISO 23125
Requirements applying
EN ISO 13849 risk analysis
Conclusion
2 Further experiences out of Translation problems “How
the EN ISO 13849 application to get EN ISO 13849 diagrams”?
Multiple safety functions for
EN ISO 13849 requirements
3 Summary out of the EN ISO 13849
application
“Safety related control systemsfor machinery“
ST/Beck -30-09.09.10
Technical
layout (Mechanic,
Hydraulik. Hard-/
Software)
Logical
structure of safety
functions according
EN 954-1
Difficulties in application of EN ISO 13849
Safety function based on EN 954-1 has been a
1:1 relationship
Translation from
Technical layout
to
Logical structures of
EN 954-1 categories
“relative easy”
for technicians
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ST/Beck -31-09.09.10
Difficulties in application of EN ISO 13849
From the point of view of a machine tool (MT) builder …
How to translate safety function into EN 13849?
Technical
layout (Mechanic,
Hydraulik. Hard-/
Software)
Structure
of EN 13849
functions safety
block-diagrams
How to translate from
Technical layout
to
EN 13489 safety
block-diagrams?
?
“Safety related control systemsfor machinery“
ST/Beck -32-09.09.10
0 General Introduction The company of INDEX
1 Practical application of Workpiece clamping device
EN 13849 to Machine Tool as EN 13849 safety function
Requirements according
EN 12415 // EN ISO 23125
Requirements applying
EN ISO 13849 risk analysis
Conclusion
2 Further experiences out of Translation problems “How
the EN ISO 13849 application to get EN ISO 13849 diagrams”?
Multiple safety functions for
EN ISO 13849 requirements
3 Summary out of the EN ISO 13849
application
Overview
Structure for the Presentation
“Safety related control systemsfor machinery“
ST/Beck -33-09.09.10
Difficulties in application of EN ISO 13849
Safety functions based on EN 13849 have a
1:n relationship
SF2: Werkstückspannen im Stillstand (Anlauf verhindern bei falschem Spannzustand)
S1
Spannwegkontrolle
K1 + T1
NCU S840D
+ SINAMICS
Blatt KR5701.51371 (Seite 515)
MK2
Standard SPS Blatt
KR5701.51371 (Seite 515)
SF3: Werkstückspannen unter Drehzahl (lösen verhindern)
K1 + T1
NCU S840D
+ SINAMICS
Blatt KR5701.51371 (Seite 515)
K2
Standard SPS Blatt
KR5701.51371 (Seite 515)
G1
Motorgeber Werkstückspindel
Spannmechanik
SF4: Spindel stillsetzen bei Druckverlust
S2
Drucküberwachung
MK2
Standard SPS Blatt
KR5701.51371 (Seite 515)
K1 + T1
NCU S840D
+ SINAMICS
Blatt KR5701.51371 (Seite 515)
Spannmechanik
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SF5: Druckänderung verhindern unter Drehzahl
K1 + T1
NCU S840D
+ SINAMICS
Blatt KR5701.51371 (Seite 515)
K2
Standard SPS Blatt
KR5701.51371 (Seite 515)
G1
Motorgeber Werkstückspindel
Gesteuertes Druckventil
SF2 und SF4 sind bei BGIA Betrachtung nicht abgebildet. Kein Induktivgeber in SF2 bei BGIA.
PLr c weil bei Fräsmaschinen d zum Einsatz kommt.
K1 + T1
Sicherheitssteuerung
Spannungsversorgung für Ventilsteuerung
wird über PROFISAFE geschaltet
Difficulties in application of EN ISO 13849
Safety functions based on EN 13849 have a
1:n relationship
“Safety related control systemsfor machinery“
ST/Beck -35-09.09.10
0 General Introduction The company of INDEX
1 Practical application of Workpiece clamping device
EN 13849 to Machine Tool as EN 13849 safety function
Requirements according
EN 12415 // EN ISO 23125
Requirements applying
EN ISO 13849 risk analysis
Conclusion
2 Further experiences out of Translation problems “How
the EN ISO 13849 application to get EN ISO 13849 diagrams”?
Multiple safety functions for
EN ISO 13849 requirements
3 Summary out of the EN ISO 13849
application
Overview
Structure for the Presentation
“Safety related control systemsfor machinery“
ST/Beck -36-09.09.10
Summary
- out of the EN ISO 13849 application
1. For EN ISO 13849 application there is no description or guideline how
to “translate” technical structures into EN ISO 13849 based safety
block structures for EN ISO 13849 evaluation and calculation.
2. EN ISO 13849 beginners are not able to understand and apply EN
ISO13849 standard without (foreign) introduction and practical
training.
3. The need to specify and define multiple EN ISO 13849 safety functions
for the evaluation of one physical technical safety structure requires
great efforts which SME seldom are able to spend.
4. Different level of safety requirements inside EN 954-1 based C-
standards in comparison to EN ISO 13849 based risk analysis lead
to great uncertainty and trouble among EN ISO 13849 applicants.
5. The “high end PLr” of EN ISO 13849 based risk analysis often is much
beyond the technical “state of the art”. It's realization is difficult, very
expensive and causes most further problems in machine operation.
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ST/Beck -37-09.09.10
Recommendation- out of the experience of the EN ISO 13849 application
1. There should be a written guideline how to “translate”
technical structures into EN ISO 13849 based safety block
structures in general
2. There should also be a guideline how to apply EN ISO
13849 calculation for EN ISO 13849 based safety block
structures in general
3. The EN ISO 13849-1 and ISO 14121 risk assessment should
be synchronized and harmonized!
4. The safety requirements in C-Standards – based on experts
experience – have to be the leading value in EN ISO 13849
“translation” of these standards!
“Safety related control systemsfor machinery“
ST/Beck -38-09.09.10
Thank you for your attention!
Questions?
Eberhard Beck Head of control techniques INDEX-Werke
EU-Symposium
“Safety related control systems for machinery”