In today’s industrial landscape, where automation of production processes plays a pivotal role, technical documentation becomes an indispensable component of any project involving the design and construction of machinery. This documentation not only ensures compliance with legal regulations but also forms the foundation for operational safety and efficiency. Specifically, the Machinery Directive 2006/42/EC mandates that manufacturers prepare and maintain appropriate documentation for each machine introduced to the European Union market. This article discusses how to properly prepare technical documentation in accordance with the requirements of this directive.
Table of Contents
Technical Documentation: Definition
Technical documentation is a collection of documents that detail the design, operation, installation, and maintenance of a machine. This documentation is essential to demonstrate that a machine meets all essential health and safety requirements. According to the Machinery Directive 2006/42/EC, comprehensive technical documentation should include:
- General description of the machine
- Assembly drawings and diagrams
- Calculation documents and test results
- Instructions for assembly, commissioning, use, and maintenance
- Risk assessment
- EC Declaration of Conformity
- Operating instructions
Technical Documentation: General Description of the Machine
The general description of the machine should include basic information about its purpose, operating principles, and main structural components. This description should cover:
- Name and type of machine
- Manufacturer and contact details
- Purpose and scope of application
- General description of the design and main components
A sample general description might look like this:
Name and type of machine: Robotic welding station XYZ-100
Manufacturer: ABC Robotics, Industrial Street 1, 00-001 Warsaw
Purpose: Robotic welding station designed for automatic welding of metal components in the automotive industry
Design description: The station consists of a robotic arm, control unit, welding source, and tooling system for component clamping. The robotic arm is made of lightweight aluminum alloys and has six degrees of freedom, allowing precise positioning of the welding tool. The control unit is equipped with the latest software for programming and monitoring welding processes. The tooling system includes clamping modules and rotary tables for precise positioning of welded components.
Assembly Drawings and Diagrams
Assembly drawings and diagrams are crucial elements of technical documentation. They should include:
- Assembly drawings showing the entire machine and its main subassemblies
- Electrical, pneumatic, and hydraulic diagrams
- Detailed drawings of individual components
Assembly drawings depict the machine from various perspectives, allowing for a detailed understanding of its construction. They should include all critical dimensions and descriptions of individual elements. Electrical, pneumatic, and hydraulic diagrams should be clear and contain all necessary information regarding connections, components, and their functions. In the context of a robotic welding station, these drawings must account for connections between the control unit, robotic arm, welding source, and tooling.
Calculation Documents and Test Results
These documents should include all technical calculations and test results conducted to confirm the machine’s compliance with relevant standards and requirements. This section of the documentation should include:
- Strength calculations (FEM)
- Results of strength, functional, and safety tests
- Reports from laboratory and field tests
Strength calculations (FEM) allow for the assessment of the machine’s structural integrity under various loads. The results of these calculations are essential to confirm that the machine is safe to use. Test results for strength and functionality should be documented and include detailed descriptions of the tests conducted, results obtained, and conclusions drawn. For example, strength tests for a robotic arm may involve simulations of dynamic and static loads, while functional tests may include checking the precision of movements and reliability of the welding system.
Instructions for Assembly, Commissioning, Use, and Maintenance
These instructions should be clear and understandable for users and service personnel. They should include:
- Detailed instructions for assembling and commissioning the machine
- Instructions for daily use and maintenance
- Safety recommendations and precautions
Assembly instructions should guide the user step by step through the process of assembling the machine, from assembling the main components, through electrical, pneumatic, or hydraulic connections, to commissioning the machine.
Usage instructions should include detailed descriptions of the machine’s functions, operating methods, and maintenance procedures to ensure long-term and trouble-free operation. Safety recommendations, which users must follow, are also crucial. For example, assembly instructions for a robotic welding station should include steps for safely assembling the robotic arm, connecting the control unit, and calibrating the welding system.
Risk Assessment
Risk assessment according to PN-EN ISO 12100:2012 is an integral part of technical documentation. It allows for the identification and evaluation of potential hazards associated with machine use and the determination of countermeasures. The risk assessment should include:
- Identification of potential hazards
- Risk assessments for individual hazards
- Proposed protective measures and design modifications
The risk assessment process begins with identifying all possible hazards that may occur during machine use. Each hazard is then assessed in terms of the likelihood of its occurrence and potential consequences. Based on this assessment, decisions are made regarding the implementation of appropriate protective measures, which may include design modifications, installation of additional safeguards, or the introduction of safety procedures. In the context of a robotic welding station, risk assessment may include evaluating risks associated with welding radiation, gas and dust emissions, and the possibility of the robotic arm colliding with operators or other station elements.
EC Declaration of Conformity
EC Declaration of Conformity is a document in which the manufacturer confirms that the machine meets all the requirements of the Machinery Directive 2006/42/EC. It should include:
- Manufacturer’s details
- Description of the machine
- Statement of conformity with relevant harmonized standards
- Signature of the person authorized to represent the manufacturer
The EC Declaration of Conformity must be prepared before the machine is placed on the market and must be included in the technical documentation. The manufacturer must also retain a copy of this declaration for a specified period, usually at least 10 years from the date the machine is placed on the market. An example declaration of conformity for a robotic welding station may include confirmation of compliance with standards related to electrical safety, structural integrity, and health and environmental protection.
Operating Instructions
Operating instructions are one of the most important elements of technical documentation. They should include:
- Detailed information on installation, commissioning, and use of the machine
- Instructions for maintenance and repair
- Information on safety and health protection
- Recommendations for disposal and dismantling of the machine
Operating instructions should be written in a language understandable to users and contain all necessary information to allow safe and effective use of the machine. For machines sold in international markets, operating instructions must be available in the appropriate languages. In the case of a robotic welding station, operating instructions should detail procedures for safely starting and stopping the welding process, operating the control panel, maintaining the welding system, and recommendations for protection against welding radiation and harmful substance emissions.
Technical Documentation: Importance in Industrial Automation
In the context of industrial automation, technical documentation plays a crucial role in ensuring that machines operate according to design assumptions and meet safety requirements. This documentation is essential at every stage of a machine’s life, from design through production to use and maintenance.
Technical Documentation: Role in Automation of Production Processes
Technical documentation allows for the precise definition of all technical and operational parameters of machines. This is particularly important in automation of production processes, where accuracy and reliability are key. Thanks to technical documentation, engineers can conduct strength calculations (FEM), analyze potential hazards, and develop preventive measures.
Examples of Technical Documentation Applications in Machine Design
During machine design, technical documentation allows for a detailed description of all constructional and operational aspects of the machine. This enables precise planning of the production process and ensures that all components and systems will operate according to assumptions. Technical documentation is also essential for conducting risk assessment according to PN-EN ISO 12100:2012 and preparing the EC Declaration of Conformity.
Technical Documentation: Steps to Preparation
Sample Steps in Creating Technical Documentation
- Gathering Data and Information
- Collecting all necessary technical and operational information
- Consultations with industry experts and design offices
- Creating Schematics and Technical Drawings
- Developing detailed construction drawings
- Machine design considering safety requirements
- Preparing Operating and Maintenance Instructions
- Writing clear and understandable instructions for operators and service personnel
- Including aspects of production automation and Industry 4.0
The Importance of Safety Audit and Risk Assessment According to PN-EN ISO 12100:2012
Safety audit and risk assessment according to PN-EN ISO 12100:2012 are key elements in the process of creating technical documentation. They allow for the identification and evaluation of potential hazards associated with machine use and the determination of appropriate protective measures. A safety audit involves a detailed assessment of all aspects related to machine safety, including design, operation, and handling procedures.
Requirements for Risk Assessment
Risk assessment according to PN-EN ISO 12100:2012 should include:
- Identification of potential hazards at every stage of the machine’s life, from design to use
- Risk assessments associated with each hazard
- Determination of countermeasures to minimize risk
- Documentation of all risk management activities
| Error | Description | Consequences | How to Avoid |
|---|---|---|---|
| Lack of detailed instructions | Assembly, commissioning, use, or maintenance instructions are too general and incomplete. | Possibility of improper machine use, leading to accidents and damage. | Create detailed, step-by-step instructions with images and diagrams. |
| Inaccurate risk assessment | Incomplete or incorrect identification of potential hazards. | Neglecting potential hazards can lead to unforeseen accidents and non-compliance with safety regulations. | Conduct comprehensive risk assessment according to PN-EN ISO 12100:2012. |
| Lack of appropriate drawings and diagrams | Technical drawings and diagrams are incomplete or inaccurate. | Difficulty in assembling and servicing the machine, increased risk of construction errors. | Create detailed drawings with descriptions and dimensions, verified by experienced engineers. |
| Improper or incomplete declarations of conformity | The declaration of conformity lacks all required information or is incorrectly prepared. | Inability to place the machine on the EU market, potential financial penalties, and legal liability. | Ensure the declaration of conformity complies with the requirements of the Machinery Directive 2006/42/EC. |
| Lack of documentation translation | Documentation is not available in the official language of the country where the machine is sold. | Users may not understand the instructions, leading to improper machine use and accidents. | Translate documentation into appropriate official languages by professional technical translators. |
Technical Documentation: Legal Requirements and Harmonized Standards
Introduction to the Machinery Directive 2006/42/EC
The Machinery Directive 2006/42/EC is the main legal act regulating the introduction of machines to the EU market. It imposes an obligation on manufacturers to ensure that all machines meet specified health and safety requirements. Compliance with the directive can be achieved by applying appropriate harmonized standards.
The Role of Harmonized Standards in Creating Technical Documentation
Harmonized standards, such as PN-EN ISO 12100:2012, provide detailed guidelines for designing safe machines and risk assessment. Applying these standards facilitates the CE certification of machines and CE marking. Harmonized standards form the basis for demonstrating machine compliance with the requirements of the Machinery Directive 2006/42/EC.
CE Marking and CE Certification of Machines
CE marking confirms that a machine meets all essential health and safety requirements specified by EU directives. To obtain CE marking, the manufacturer must prepare appropriate technical documentation, conduct a safety audit, and obtain an EC Declaration of Conformity.
Technical Documentation: Practical Tips for Engineers
How to Conduct Engineer Outsourcing and Project Management in the Context of Technical Documentation?
Engineer outsourcing can be an effective way to gain the specialized knowledge needed to prepare technical documentation. However, it is crucial that this process is well-organized and supervised to ensure compliance with design and regulatory requirements. Project management in the context of technical documentation requires close collaboration between different teams and attention to detail.
Examples of Best Practices from Design Offices
Design offices often have extensive experience in preparing technical documentation. Collaborating with such offices can significantly speed up the documentation creation process and ensure its high quality. Design offices can also assist in conducting safety audits and preparing risk assessments according to PN-EN ISO 12100:2012.
Technical Documentation in the Context of Industry 4.0
How Does Industry 4.0 Affect Technical Documentation Requirements?
Industry 4.0 introduces new technologies, such as SCADA and PLC programming, which require detailed technical documentation. Integrating these technologies into the production process increases the complexity of documentation but simultaneously improves its functionality and efficiency. Technical documentation must account for all aspects related to new technologies to ensure full compliance with regulatory requirements.
Integration of SCADA, PLC Programming, and Other Technologies in Documentation
Creating technical documentation for systems integrated with SCADA and PLC programming requires a detailed description of all components, interfaces, and operational procedures. This documentation is essential for the proper installation, commissioning, and maintenance of systems. In the context of industrial automation, technical documentation must also consider aspects related to Industry 4.0, such as system integration, process automation, and data management.
Key Takeaways on Technical Documentation
Technical documentation is an essential element in ensuring the safety and operational efficiency of machines. It enables compliance with legal requirements, conducting safety audits, and effective project management. Well-prepared technical documentation is the foundation upon which all stages of a machine’s life are built, from design through production to use and maintenance.
The Future of Technical Documentation in the Context of Technological and Regulatory Development
As new technologies develop and regulations tighten, the importance of technical documentation will continue to grow. Engineers must be prepared to continuously update and adapt documentation to changing market and legal requirements. Technical documentation must evolve to meet the demands of Industry 4.0 and ensure full compliance with the Machinery Directive 2006/42/EC.
Technical Documentation: FAQ
The Machinery Directive 2006/42/EC is an EU legal act regulating the introduction of machines to the market and their safety. It aims to ensure that all machines introduced to the EU market meet minimum health and safety requirements for users.
The manufacturer is responsible for ensuring a machine’s compliance with the Machinery Directive. For imported machines, the responsibility lies with the importer or the manufacturer’s authorized representative in the European Union.
Technical documentation is a collection of documents describing the design, operation, installation, and maintenance of a machine. It is crucial because it allows for demonstrating that a machine meets the requirements of the Machinery Directive 2006/42/EC.
Technical documentation should include: a general description of the machine, assembly drawings and diagrams, calculation documents and test results, instructions for assembly, commissioning, use, and maintenance, risk assessment, EC Declaration of Conformity, and operating instructions.
The EC Declaration of Conformity is a document in which the manufacturer or their authorized representative confirms that a machine meets all the requirements of the Machinery Directive 2006/42/EC and other applicable directives. It must include the manufacturer’s details, a description of the machine, a statement of conformity with harmonized standards, and the signature of an authorized person.
Risk assessment according to PN-EN ISO 12100:2012 is a mandatory element of technical documentation. It involves identifying and evaluating potential hazards associated with machine use and determining appropriate protective measures.
Non-compliance with the Machinery Directive can result in a ban on placing the machine on the EU market, withdrawal of the machine from the market, and financial penalties for the manufacturer or importer. It can also lead to legal liability in the event of accidents related to the machine.
Yes, technical documentation, including operating instructions, must be available in the official language of the country where the machine is introduced to the market. This is crucial to ensure that users can correctly and safely operate the machine.
The manufacturer must retain the technical documentation for at least 10 years from the date the machine is placed on the market. This is required to allow market surveillance authorities to conduct compliance checks with the Machinery Directive requirements.
The most common mistakes include a lack of detailed operating and maintenance instructions, inaccurate risk assessment, lack of appropriate drawings and diagrams, and improper or incomplete declarations of conformity. It is important that the documentation is detailed, complete, and compliant with the requirements of the Machinery Directive 2006/42/EC.