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Safety Lifecycle Navigator

Safety Lifecycle Navigator
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Safety Lifecycle Navigator

Product catalog summary
Introduction
This document provides guidelines for safety technology in machinery, focusing on simplifying safety measures throughout a machine's lifecycle. It stresses adherence to current standards and regulations, while recommending additional autonomous checks.
Legal and Copyright Information
The guideline is copyrighted and requires written consent from the Safety Alliance for reproduction or modification.
Objectives of Safety Technology
The goals include preventing accidents, protecting workers' health, and avoiding costs from machine malfunctions. The Safety Alliance supports effective planning and implementation of safety technology.
Machinery Safety with Baumüller
Baumüller offers integrable safety solutions for automation systems, complying with EN ISO 13849, and aims to simplify complex standards.
The Safety Alliance
A consortium focused on functional safety technology, offering a platform that supports various communication networks and safety profiles.
Safety Lifecycle Navigation
Outlines a step-by-step process for achieving machine safety, including safety planning, risk assessment, and validation.
Route Planning and Legal Basis
Emphasizes understanding and adhering to legal requirements and standards, using a simplified V model of the software lifecycle.
Conclusion
The Safety Lifecycle Navigator assists in implementing safety technology efficiently, with guidance from the Safety Alliance.
Legal Basis and Responsibilities
Discusses the Machinery Directive, defining responsibilities for compliance with European Community requirements.
Standards and Risk Assessment
Mandates risk assessment according to EN ISO 12100, with harmonized standards like IEC 62061 and EN ISO 13849-1 providing guidelines.
Safety Planning and Verification
Outlines roles, responsibilities, and qualifications for project execution, with tools like SAFEPROG for application development.
Risk Assessment and Mitigation
Guides the development of safety concepts to reduce risks, emphasizing integration into the design process.
Risk Assessment Process
An iterative process involving risk analysis and estimation, guided by standards like EN ISO 12100.
Risk Analysis
Involves specifying machine limits, identifying potential dangers, and estimating risks.
Hazard Identification
Categorizes hazards into mechanical, electrical, and ergonomic, highlighting the complexity of identification.
Risk Estimation
Assesses the degree of damage and probability of occurrence, considering factors like injury likelihood and exposure frequency.
Risk Reduction Measures
Outlines modifying machine construction and implementing technical safety equipment based on performance level (PL value).
Example Machine Risk Assessment
Uses a lathe machine to illustrate risk assessment, recommending specific measures for identified risks.
Safety Function Specification
Describes implementing safety functions like emergency-stop buttons and safe position switches.
Safety Functions
Details safety functions such as stopping after opening the safety door and protection against unintended restart.
Validation Planning
Specifies validation plans for testing safety functions, detailing test actions and expected responses.
Implementation
Involves selecting suitable components and designing the system, using SISTEMA software for performance level calculations.
Component Selection
Components must support a two-channel structure to achieve the required safety level (PL d).
System Design
Involves safe communication protocols and pulsed signals to detect short circuits.
Module Design
Describes safety application with a block diagram, undergoing verification, simulation, and testing.
Conclusion
Emphasizes early performance level verification using SISTEMA to avoid project deviations and costs.
Specifications
Specifies safety functions with parameters and device/signal names.
Procedures
Describes navigation through the safety lifecycle, including module and integration tests.
Testing and Validation
Provides detailed test actions and expected responses, emphasizing documentation of results.
Standards and Recommendations
Follows programming guidelines like EN ISO 13849 for code readability and testability.
Results and Documentation
Documents test results in reports, verifying safety application requirements.
Safety Circuits Test Results
Documents tests on safety circuits, ensuring machine safety by switching to a torque-free state.
Safety Lifecycle Navigation
Outlines the process of ensuring machine safety through the V model.
Contact and Support
Provides contacts for legal, development, risk assessment, and certification support.
Bibliography
References standards and publications related to machinery safety.
Figures and Tables
Includes figures illustrating safety processes and methodologies.
Products by Baumüller
Offers automation and drive solutions emphasizing modularity, scalability, and compliance with safety standards.
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Catalog excerpts

Safety Lifecycle Navigator-1

SAFETY ALLIANCE n BAUMULLER

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Safety Lifecycle Navigator-3

Please observe the following notes Target group of this document This guideline is aimed at all persons using safety technology or want to. guidelines, standards and regulations for safety technology are mentioned, It is intended to simplify the entry into the technology of safe machines, but the guideline is not exhaustive. Becoming familiar with valid guidelines, in addition to the trainings and services offered by the Safety Alliance standards, and regulations for the application is required in any case. members, and to give you an overview on safety technology basics and necessary measures...

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Safety Lifecycle Navigator-4

Your safe way through the safety lifecycle in mechanical engineering

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Machinery safety step by step 5 Objectives of safety technology use 6 Machinery safety with BaumOller 7 Open platform for functional safety technology 10 Your benefits as mechanical engineer and operator 10 Advice and support on the way to the safe machine 11 Involved authors and companies 11 Navigation through the safety lifecycle 12 Your starting point - the example machine 13 Start - Legal basis 15 Waypoint 3 - Specification of the risk minimization 30 You have reached your destination! 55 What's next? Traffic information and points of interest 56 Your contact...

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Safety Lifecycle Navigator-6

Machinery safety step by step

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Machinery safety step by step Objectives of safety technology use In today´s industrial production, more and more complex machines and technical systems are used. On the one hand, safety technology use should exclude danger for people, environment and machines or at least reduce it to an acceptable level. On the other hand, the availability of machines and production facilities should not be more limited than absolutely necessary. Thus, basic objectives for safety technology use are: • voidance of accidents which can be caused by incorrect a behavior of machines or people • reventive health protection...

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Safety Lifecycle Navigator-8

Machinery safety    with Baumüller

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Machinery safety with Baumüller A guideline for safety of machinery The European machine manufacturers and users must comply to the safety requirements of the standard EN ISO 13849, which has come into force. The standard is supposed to offer an uniform level throughout Europe for the protection of individuals, the environment and the systems against technical errors or operating errors. This is supposed to be performed without affecting the productivity of the machines and installations and is the responsibility of the machine manufacturers as well as of the users. In the Safety Lifecycle Navigator...

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Safety Lifecycle Navigator-11

Open platform for functional safety technology The Safety Alliance is an association of automation manufacturers, technology and solution providers, specialists and service providers for functional safety technology. With the formation of the Safety Alliance, the proven concept of an open technology platform, based on scalable and interoperable software components, becomes a comprehensive solution architecture for functional safety. Leading automation manufacturers, solution providers, service providers and users of safety technology complement each other’s competencies with regard to marketing,...

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n SAFETY BAUMULLER allianceAdvice and support on the way to the safe machine The Safety Lifecycle Navigator is an overview document for better understanding the processes related to the "safe machine" using a specific example. You will learn, among other things, that "following recipe instructions" is unfortunately not possible in the field of machinery safety. Each safety solution is as unique as the machine, for which it is implemented. This way, a customized safety concept is developed, step by step, from one waypoint to the next. Many steps on the way to the safe machine will become easier...

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Safety Lifecycle Navigator-13

Navigation through the Safety Lifecycle

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Navigation through the safety lifecycle Your starting point - the example machine Figure 1: Example machine without safety equipment The example machine displayed in Figure 1 is the starting point of our considerations. It is a lathe used for machining workpieces that are fixed by clamping jaws in a fast rotating tool. Workpieces are to be clamped and adjusted regularly before each new machining process. The example machine is displayed without installed safety measures. This simplified example shows the individual steps on the way to the safe machine. Nevertheless, the display is complete as...

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Navigation through the safety lifecycle Route planning START EN ISO 13849 Figure 6: Simplified V model of the software lifecycle Legal basis Waypoint 1 Safety planning Specification of the safety function Validated software Safety-related Validation software specification Waypoint 4 Validation planning System design Integration test (incl. wiring test) Module design Module test Figure 2: Definition of the waypoints in conformity with EN ISO 13849-1:2008 (D) The "map" with the "route plan" in Figure 2 describes the shortest way from the example machine to the finish of the safe machine, reached...

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Navigation through the safety lifecycle n Which guidelines and standards are valid for my product? The machine specification must be completed. General procedure Machinery Directive and CE marking Quote from the Machinery Directive (MRL) [1]: "The manufacturer of machinery or his authorized representative must ensure that a risk assessment is carried out for the machinery which he wishes to place on the market. For this purpose, he should determine which are the essential health and safety requirements applicable to his machinery and in respect of which he must take measures." The CE marking...

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Navigation through the safety lifecycle n {SiA F E T Y BAUMULLER alliance Responsibility Manufacturers and retailers have the legal obligation to comply with European Community requirements for the equipment and operation of machines and systems. The manufacturer or his authorized representative established in the Community is responsible for the compliance with the provisions, the issue of an "EU declaration of conformity" (for ready-to-use machines) or a "declaration by the manufacturer" (for not ready-to-use machines and safety components) as well as the affixing of the CE marking. If this...

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