Variable working conditions
During automatic operation, adjustment, cleaning, troubleshooting and maintenance, people approach different hazardous areas.
/ INDUSTRIAL SOLUTION
14
Machine Safety
Manage machine risks through safe design, protective measures and validated control functions.
We handle machine safety with a life cycle approach, from risk assessment to PLr/SIL determination, safety PLC, protective interlocking, safe movement and validation.
Explore the solution
Do not just cover the danger with a guard; Make human, machine and production interaction safe with systematic risk reduction.
Control system risk
A single sensor, contactor or software fault may cause the safety function to fail at the time of request.
Unconfirmed change
Line revision, speed increase or new operating mode; It may override existing risk assessment and security functions.
/ ISO 13849 AND IEC 62061From risk assessment to validation,
From risk assessment to validation,
monitorable machine safety.
Machine safety; It begins with identifying hazards, estimating the risk, and mitigating it primarily through design. Protectors, safety devices and safety-related control functions are designed together for remaining risks.
ISO 12100Risk assessment and reduction
PLr / SILRequired performance target
ValidationAnalysis and function test
- Identify hazardAssess crush, cut, jam, impact, ejection and unexpected movement scenarios.
- Define functionExplicitly identify stop, lockout, speed monitoring and restart conditions.
- Prove performanceArchitecture, component verify reliability, diagnosis, and common cause error assumptions.
From danger to safety function,
every decision can be monitored.
ISO 13849 and IEC 62061 approach; It combines risk assessment, requirement, design, implementation and validation steps in the same safety goal.
Hazard and task
analysis
Machine limits, usage patterns and exposure scenarios is determined.
→PLr or SIL
determination
The required performance is defined for each security function.
→Architecture and
integration
Sensor, safety PLC, driver and end elements are integrated.
→Verification and
validation
It is proven that the requirements are met through calculations, analysis and tests.
/ ENGINEERING SCOPEMechanical protection, electrical and software
Mechanical protection, electrical and software
in the same safety function.
Each function; It is handled independently, taking into account the way the machine is used, the severity of danger, exposure and the possibility of avoidance.
Risk assessment
Machine limits, life stages, tasks, hazards and risk reduction measures are documented.
Safety requirement specification
Safe situation, reaction duration, operating mode, reset and restart conditions are defined.
Safety PLC and network
Safety inputs/outputs, safety communication and zone architecture are designed with error behaviors.
Safe drive functions
Functions such as STO, SS1, SLS and safe direction are designed to be implemented. It is selected and parameterized according to the risk.
PL or SIL verification
Category/architecture is calculated to meet the target performance with MTTFd, DC, CCF or PFHd data.
Function validation
Normal operation, sensor error, energy loss, reset and reboot scenarios are tested against acceptance criteria.
First reduce the danger by design,
then protect and inform.
In machinery safety, the safety-related control system alone is not the solution; structural design, protective measures and usage information are part of the same risk mitigation strategy.
MACHINE HAZARD
01Safe designReduce danger at source
02ProtectiveDistance and physical barrier
03Safety controlDetect and stop safely
04InformationWarning, instruction and training
ACCEPT POSSIBLE RISK
From risk scenario to field testing,
six controlled steps
- 01Determine machine limits
Usage scenarios covering the product, operator, maintenance and all operating modes are drawn up.
- 02Assess the risk
Analyze danger, exposure, possible harm and possibility of avoidance.
- 03Define the function
Safe state, input, logic, output, response time and PLr/SIL target are written.
- 04Design the system
Sensor, safety PLC, driver and actuator architecture. is applied.
- 05Verify and validate
Performance calculation and function and error scenario tests are completed.
- 06Manage change
Revision, maintenance and bypass operations are continued with controlled records.
Verified safety functions at every point where humans and automation meet
Robotic cells
Door locking, area scanning, safe speed and maintenance mode scenarios.
Press and assembly lines
Two-hand control, light curtain, mold zone and transfer safety.
Conveyor and intralogistics
Emergency stop zones, pinch points, access and safe restart.
Special machinery
Application specific risk reduction in cutting, wrapping, packaging and moving equipment.
How we turned a similar need
into an operating solution.
Customer and facility information has been anonymized to meet confidentiality obligations.
ANONYMOUS PROJECTRELATED SOLUTION
Integrated Automation and Safety Transformation on an Automotive Production Line
Fragmented control practices were unified through a standard PLC/HMI architecture, controlled operating modes and verifiable safety functions.
Read the story →
ANONYMOUS PROJECTRELATED SOLUTION
Unmanned Crane and Continuous Material Flow in Steel Production
Heavy-load movements were converted into a safe, traceable crane operation driven by production priorities and stock data.
Read the story →Let’s review the safety scope
with the right discipline.
Share the machine or process boundary so the relevant safety engineering team can assess the next step.
Request a safety scope review Your request is routed directly to the relevant engineering team.