Rockwell Smart Machine Safety

Description

Smart Machine Safety is about enabling the equipment, machinery, and devices in a manufacturing plant and industrial operations to be connected and can provide real time information as well as be controlled via intelligent software.

“Safety as a core system function”

• Global Compliance – Global Machines
• Reduced Costs & Common Designs
• Increased Productivity
• Reduced Floor Space and Direct Labor
• Improved Ergonomics
• Reduced Injuries

How SMART assets evolve safety

Predictive maintenace:

Operations of safety devices per shifts are captured

Monitoring number of operations helps predict when device is at end of life

Information is available for maintenance staff to replace device

Device can be replaced at next planned maintenance schedule

Machine uptime from Smart Safety data

Machine operator opens interlocked guard door to fix tape. Device operation is logged in system

Production manager has all data available on safety device actions

Production manager and machine operator discuss reason of frequent access. Tape causing problem can be replaced

Machine running more efficiently with less maintenance required

How to build Smart Machine Safety?

• New tools: Emergence of Global Standards – ISO, IEC, Standard Machine Designs that are Globally Compliant
• New Safety Technologies – Tools for Improved
• Machine Performance
• New Design approaches – Passive, Configurable and Lockable

Functional Safety Lifecycle

Step 1: Risk Assessment – The Foundation

Provides Safety Performance Level – Design Target

Creates the Foundation of the Safety System Functional

Requirements, System Design and Validation Protocol

Shows “Due Diligence” and Global Compliance (Ref. ISO 12100)

Step 2: Safety Function Definition

Safety Functions are a combination of input, logic and output devices

Step 3: Safety Functions: Characteristics & Block Diagram

Typical safety function diagram

• The machine designer shall select an architecture – circuit structureCat B, 1, 2, 3 or 4
• Determine MTTFd for the Channel
• Calculate Diagnostic Coverage (DC)
• Evaluate Common Cause Failure Protection
• Determine Performance Level – PLr =< PL? This is Verification

Step 4: SAFETY SYSTEM INSTALLATION & VALIDATION

Verification and Validation plans include:

• Installation & Wiring Verification
• Operational Verification & Validation
• Network Verification & Validation
• Controller Verification & Validation

Includes:

Functional Testing & FaultInjectionTesting

Step 5: Maintain & Improve

There should be documented systems in place for change management/modification