The standard PN-EN-ISO 11161 is a cornerstone document for ensuring the Security of Integrated Production Systems. Its primary goal is to guarantee that complex production systems, comprising numerous interacting machines, are designed and operated safely for both operators and the environment. Below, we outline the critical aspects of this standard, which are vital for machine designers and industrial automation integrators.
Table of Contents
Holistic Approach to Security
The PN-EN-ISO 11161 standard emphasizes that an integrated production system should be treated as a whole rather than a collection of individual components. Risk assessment and the implementation of protective measures must encompass the entire system, considering interactions between individual machines. This approach ensures comprehensive protection and minimizes risks associated with unforeseen interactions among different system components. In integrated production systems, risks may arise not only from the operation of individual machines but also from their mutual interactions. Therefore, risk assessment must be conducted at the system level, not just for its individual components.
Security of Integrated Production Systems: System Boundary Specification
Defining the boundaries and functionalities of a production system is crucial for proper risk assessment and ensuring security. System boundaries include physical and operational constraints, as well as interfaces between machines. This specification allows for a precise understanding of which system elements must be included in the risk assessment process. The functional documentation should contain detailed descriptions of all machines and devices within the system, their interfaces, and operational and maintenance procedures. Such an approach ensures that all security aspects are considered at the system design stage.
Risk assessment must include all machines and devices that are part of the integrated production system, considering interactions between them.
Identifying and Designating Task Zones
Designating task zones where operators can safely perform their duties is a key element of the standard. These zones must be clearly marked and equipped with appropriate protective measures, such as machine guards, presence detection systems, locks, etc. Designating task zones allows for effective risk management, enabling operators to perform tasks safely without exposing themselves to dangers associated with machine operation.
Various Operational Modes
The standard requires the provision of various operational modes, such as automatic, manual, or service mode, which allow for the safe execution of different tasks in the production system. Each operational mode must be appropriately designed and equipped with protective measures to ensure operator safety. Operational modes are particularly important in complex production systems, where switching between different work modes is necessary depending on the tasks being performed.
Security of Integrated Production Systems: Comprehensive Documentation
Providing detailed technical documentation is essential for users to safely and efficiently operate, maintain, and repair the integrated production system. The documentation should include information on all aspects of the system, including safety procedures, operating instructions, maintenance plans, and descriptions of interfaces between machines. Comprehensive documentation ensures that all individuals involved in system operation are aware of potential hazards and know how to perform their tasks safely. This is a crucial element of risk management and ensuring compliance with safety standards.
Security of Integrated Production Systems: Validation of Protective Measures
Before system startup, all protective measures must be verified and confirmed as effective in reducing risk to an acceptable level. This validation should include functional tests, documentation reviews, and compliance audits with harmonized standards. Validation of protective measures is crucial because it ensures that all safeguards operate as intended and effectively protect operators from hazards. It is necessary to obtain the CE mark and confirm compliance with legal requirements.
System-Level Security Measures
Protective measures must be implemented not only at the level of individual machines but also at the level of the entire production system to ensure comprehensive machine safety. Security measures must cover interfaces between machines and provide protection in case of system failure. System-level security measures include elements such as emergency stop systems, operator presence detection, and machine condition monitoring systems. All these elements must be integrated to ensure their effective operation throughout the system.
Technical documentation should contain detailed descriptions of operational, maintenance, and interface procedures between machines to ensure full compliance with the standard’s requirements.
Security of Integrated Production Systems: Muting and Blanking
Muting is the temporary automatic suspension of safety systems, such as presence sensors or light barriers, to allow materials to pass through the protective zone without triggering alarms or stopping the machine. This is particularly useful in automated production lines where regular machine stoppages would be inefficient.
Key features of muting:
- Temporariness: Muting is always time-limited and aims to allow materials to pass through the protective zone under specific, controlled conditions.
- Automation: The muting process is automatically controlled by the control system, which monitors conditions such as movement speed and object presence to ensure that muting is applied only when it is safe.
- Safety: Muting is implemented in a way that minimizes risk to operators. For example, muting may only be applied when the operator is not present in the danger zone, and presence detection systems must be active to prevent accidental entry into the hazardous area.
Example of muting application: Imagine a production line where a conveyor transports raw materials through various production stages. To ensure work continuity, the system may temporarily suspend the operation of the light barrier when the conveyor transports material through the protective zone. After the material passes, the light barrier automatically returns to active mode, protecting operators from entering the dangerous zone.
Blanking involves disabling parts of the presence detection system (e.g., sensors or light curtains) in specific areas to allow normal machine operation without interruptions. Blanking is particularly useful in situations where some machine elements or transported materials may pass through the detection zone but do not pose a threat to operators.
Key features of blanking:
- Selectivity: Blanking involves disabling only specific sensors or their parts, allowing protective functions to be maintained in other areas.
- Control: The blanking process is strictly controlled and monitored by the control system, ensuring that disabled areas do not pose a threat.
- Adaptability: Blanking can be adjusted to different production situations, allowing flexible safety management in changing work conditions. In industrial automation, this adaptability is crucial as it enables dynamic adjustment of protective systems to changing production scenarios.
| Function | Muting | Blanking |
|---|---|---|
| Definition | Temporary suspension of safety systems | Disabling parts of the presence detection system in specific areas |
| Application Example | Material passage through the protective zone in an automated production line | Normal machine operation without interruptions when some elements may pass through the zone |
| Key Features | Temporariness, automation, minimizing risk to operators | Selectivity, control, adaptability to different production situations |
The PN-EN-ISO 11161 standard highlights key aspects of ensuring the Security of Integrated Production Systems. A holistic approach to risk assessment, system boundary specification, task zone designation, various operational modes, comprehensive documentation, validation of protective measures, system-level security measures, and advanced mechanisms such as muting and blanking are fundamental elements of effective security management.
Machine designers and industrial automation integrators must consider these guidelines to ensure the safe and efficient operation of complex production systems, in accordance with the highest safety standards and legal requirements. Adhering to the requirements of the PN-EN-ISO 11161 standard not only enhances security but also optimizes production processes, minimizing the risk of downtime and failures, which translates into higher production quality and customer satisfaction.
In the context of the Machinery Directive 2006/42/EC and the Machinery Regulation 2023/1230, implementing the PN-EN-ISO 11161 standard is an essential element of ensuring compliance with regulations and obtaining CE certification for machines. This ensures that production systems can be safely used in the European market, meeting all safety and health requirements.
Industrial automation is a key component of modern production lines, enabling increased efficiency and safety of operations. Machine assemblies, integrated through advanced control systems such as SCADA and PLC programming, allow for precise monitoring and control of production processes.
The integration of automation in production processes and advanced technologies, such as industrial robots and SCADA and PLC systems, requires careful project management and regular safety audits. Outsourcing engineers and collaborating with an experienced design office can significantly enhance the efficiency and safety of production automation projects.
Ultimately, the application of appropriate protective measures and systematic monitoring and control of production system conditions, in accordance with the guidelines of the PN-EN-ISO 11161 standard, contributes to the creation of safe and reliable production lines that meet the highest quality and safety standards.
FAQ: Security of Integrated Production Systems
Answer: The PN-EN-ISO 11161 standard pertains to the security of integrated production systems, comprising multiple interacting machines. It aims to ensure that these systems are designed and operated safely for both operators and the environment.
Answer: A holistic approach means treating the integrated production system as a whole, not a collection of individual elements. Risk assessment must consider interactions between individual machines, ensuring comprehensive protection and minimizing risks associated with unforeseen interactions.
Answer: The system boundary specification includes physical and operational constraints and interfaces between machines. It is crucial for proper risk assessment and security, allowing for a precise understanding of which system elements must be considered.
Answer: Task zones must be clearly marked and equipped with appropriate protective measures, such as machine guards, presence detection systems, and locks. This allows for effective risk management and safe task execution by operators.
Answer: The standard requires various operational modes, such as automatic, manual, and service modes, to safely perform different tasks in the production system. Each mode must be designed with appropriate protective measures to ensure operator safety.
Answer: Technical documentation is essential for the safe and efficient operation, maintenance, and repair of the integrated production system. It should include information on safety procedures, operating instructions, maintenance plans, and descriptions of interfaces between machines.
Answer: Validation of protective measures involves functional tests, documentation reviews, and compliance audits with standards to confirm their effectiveness in reducing risk to an acceptable level. This is crucial for obtaining the CE mark and confirming compliance with legal requirements.
Answer: Security measures must be implemented not only at the level of individual machines but also the entire production system. This includes emergency stop systems, operator presence detection, and machine condition monitoring systems.
Answer: Muting is the temporary automatic suspension of safety systems to allow materials to pass through the protective zone without triggering alarms. Key features include temporariness, automation, and minimizing risk to operators.
Answer: Blanking involves disabling parts of the presence detection system in specific areas to allow normal machine operation without interruptions. Key features include selectivity, control, and adaptability to different production situations.