Machine safety is a pivotal aspect of any industrial environment, safeguarding not only employees from potential injuries but also enhancing the efficiency and reliability of production processes. Machines that lack proper safety measures pose significant risks to operators and nearby individuals. Effective risk management and the implementation of appropriate protective measures are essential for maintaining a safe workplace. In this context, the Machine Run Study becomes an indispensable component of ensuring safety.
Table of Contents
Machine Run Study: Key Principles of ISO 13855:2010 Standard
Structure and Scope of the Standard
The ISO 13855:2010 standard encompasses various aspects of machine safety, focusing on technical protective measures and their placement concerning the approach speed of human body parts. The document is divided into several key sections, including:
- Scope of the standard
- Normative references
- Terms, definitions, symbols, and abbreviations
- Methodology for determining minimum distances
- Detailed rules for the placement of various types of technical protective measures
The standard also specifies the approach speed values to consider when designing protective systems and how to calculate the minimum distances from the detection zone to the danger zone.
Basic Terms and Definitions
Understanding and correctly applying the ISO 13855:2010 standard requires familiarity with key terms and definitions. Here are a few:
- Total system stopping time (T): The time interval from the activation of the detection function to the cessation of the machine’s hazardous function.
- Minimum distance (S): The calculated distance between the technical protective measure and the danger zone, necessary to prevent a person or body part from entering the danger zone before the hazardous function of the machine ceases.
- Electrosensitive protective equipment (ESPE): A set of cooperating devices and/or elements used for automatic protective shutdown or presence detection, including at least a detecting device, control/monitoring devices, and output signal switching devices.
Machine Run Study: Methodology and Placement of Technical Protective Measures
Methodology for Determining Minimum Distances
Risk assessment is an integral part of the Machine Run Study. This process analyzes potential hazards associated with machine operation and identifies preventive measures to minimize risk. According to ISO 13855:2010 and risk analysis per ISO 12100:2012, engineers must consider the approach speeds of body parts, system reaction time, and the effectiveness of the applied technical protective measures. A thorough risk assessment allows for the implementation of appropriate safeguards, thereby increasing machine safety and regulatory compliance.
The ISO 13855:2010 standard presents the methodology for calculating minimum distances necessary to ensure machine safety. These formulas account for the approach speed of human body parts to the danger zone and the reaction time of the protective system. Below are detailed rules for calculating these distances.
General Formula for Calculating Total System Stopping Time and Minimum Distances:
S=(K×T)+C
where:
- S – minimum distance,
- K – coefficient dependent on approach speed,
- T – total system stopping time,
- C – additional distance based on anthropometric data.
Example Calculations for Different Approach Speeds
- Approach speed of an adult walking at normal pace (1.6 m/s)
- Assume the total system stopping time is 0.5 seconds.
- Additional distance C is 0.2 m.
S=(1.6 m/s×0.5 s)+0.2 m=0.8 m+0.2 m=1.0 m
- Approach speed of an upper limb (2.0 m/s)
- Total system stopping time is 0.4 seconds.
- Additional distance C is 0.1 m.
S=(2.0 m/s×0.4 s)+0.1 m=0.8 m+0.1 m=0.9 m
Types of Technical Protective Measures
The ISO 13855:2010 standard considers various technical protective measures used to ensure machine safety in different working conditions. Below are the most important ones:
- Light curtains and light barriers (AOPD)
- Light curtains are devices that emit light beams and detect interruptions in these beams caused by the presence of a person or body part entering the danger zone.
- Light barriers operate on a similar principle, creating an invisible barrier that, when interrupted, causes the machine to shut down.
- Laser scanners (AOPDDR)
- Laser scanners are used to monitor larger areas and can detect movement in complex spatial configurations.
- They allow precise detection of moving objects, which is particularly useful in dynamic production environments.
- Pressure-sensitive mats
- These mats respond to pressure exerted by individuals stepping on them, allowing for the detection of presence in the danger zone.
- They are used in areas where it is necessary to ensure safety while allowing free access to the machine.
- Two-hand control devices
- Require the use of both hands to activate the machine, preventing accidental start-up.
- They are used in situations where it is necessary to ensure that the operator is at a safe distance from the danger zone during machine start-up.
| Type of Technical Protective Measure | Description | Example Application |
|---|---|---|
| Light curtains | Detect interruptions of light beams in the danger zone | Production lines |
| Laser scanners | Monitor larger areas and detect movement in complex spatial configurations | High-bay warehouses |
| Pressure-sensitive mats | Respond to pressure exerted by individuals stepping on the mat | Machine maintenance areas |
| Two-hand control devices | Require the use of both hands to activate the machine | Machines with high risk of accidental start-up |
Machine Run Study: Practical Applications and Examples
Examples of Practical Application of the Standard
Here are a few examples illustrating the practical application of the ISO 13855:2010 standard in various industrial environments. Each example demonstrates how technical protective measures can be effectively implemented to ensure machine safety.
Example 1: Application of Light Curtains in a Production Line
In a manufacturing plant where fast assembly machines operate, light curtains are installed along the production line. These curtains are positioned to detect any interruption of the light beam caused by a person or body part entering the danger zone. The minimum distance between the light curtain and the danger zone is calculated according to ISO 13855:2010, considering the approach speed of the person and the protective system’s reaction time. When the presence of a person is detected in the detection zone, the machine immediately stops operating, preventing potential injuries.
Example 2: Use of Laser Scanners in a Warehouse
In a high-bay warehouse, laser scanners are used to monitor movement in the aisles between racks. These scanners are positioned at a height that allows for the detection of movement of both forklifts and workers. The ISO 13855:2010 standard is used to determine the appropriate minimum distances, ensuring that any movement in the detection zone is immediately registered.
When the scanner detects the approach of a person or vehicle to the danger zone, the system automatically halts the forklift’s movement, minimizing the risk of collisions and accidents. This solution allows the warehouse to operate efficiently while ensuring a high level of safety for all employees.
Example 3: Pressure-Sensitive Mats in Machine Maintenance Areas
In machine maintenance areas, pressure-sensitive mats are installed to protect technicians performing repair work. These mats respond to pressure exerted by individuals stepping on them, allowing for the detection of presence in the danger zone. According to ISO 13855:2010, the mats are placed at an appropriate distance from the danger zone, ensuring that the machine will automatically shut down if a technician steps on the mat during machine operation.
This solution significantly enhances safety during maintenance work, eliminating the risk of accidental machine start-up when a technician is in the danger zone. As a result, machine maintenance is safer and more efficient.
Machine Run Study: Challenges and Solutions in Standard Implementation
Common Issues Encountered During Standard Implementation
During the implementation of the ISO 13855:2010 standard, companies may encounter various challenges. Here are some common issues and proposed solutions:
- Inaccurate calculations of minimum distances
- Solution: Ensure that all calculations are accurately performed according to the standard’s guidelines. Regular training for engineers and operators can help avoid errors.
- Lack of employee awareness and training
- Solution: Organize regular training sessions on safety principles and the application of the ISO 13855:2010 standard. Ensure that all employees are aware of the hazards and know how to use technical protective measures.
- Technical issues with protective devices
- Solution: Provide regular inspections and maintenance of technical protective measures. Collaborate with equipment suppliers to ensure that devices are always fully operational.
- Difficulty adapting the standard to specific working conditions
- Solution: Tailor the standard’s implementation to specific working conditions, considering all unique aspects of the environment. Consultations with safety experts can help resolve specific issues.
The ISO 13855:2010 standard provides detailed guidelines for the placement of technical protective measures to ensure machine safety. Adhering to these guidelines minimizes the risk of injuries and enhances workplace safety. Practical examples of the standard’s application demonstrate how various technical protective measures can be effectively utilized in different industrial environments.
Industrial Automation and Machine Run Study
Industrial automation plays a crucial role in modern manufacturing facilities, where machine reliability and safety are priorities. Within this process, the Machine Run Study is a vital component that ensures all equipment operates in compliance with safety standards, minimizing the risk of accidents.
In machine design and integration with automation systems, it is essential to consider the approach speed of human body parts to the danger zone. The design office responsible for automating production processes must apply the guidelines contained in the ISO 13855:2010 standard to appropriately place technical protective measures.
This standard is also essential during safety audits, which assess machine compliance with minimum requirements and other regulations, such as the Machinery Directive 2006/42/EC and the Machinery Regulation 2023/1230. Auditors often use the results of the Machine Run Study to ensure that all equipment meets the criteria for CE certification and can safely operate in the production environment.
In the process of assessing machine compliance, the CE mark is awarded only to devices that have passed rigorous safety tests. The industrial automation integrator must ensure that all system components, including machine guards and PLC programming systems, operate in accordance with harmonized standards. Production automation without appropriate protective measures could lead to dangerous situations, making the Machine Run Study an indispensable step in the design and implementation process.
In the context of rapidly developing industrial automation, the Machine Run Study is also crucial when adapting machines to minimum requirements. Outsourcing engineers and specialists in production process automation can be a beneficial solution for companies needing support in implementing advanced safety systems.
Conclusions and Recommendations
- Recommendations for designers and engineers: Strictly adhere to the ISO 13855:2010 standard guidelines when designing machine safety systems. Regular reviews and updates of protective systems are crucial for maintaining high safety levels.
- Importance of continuous improvement of protective measures: As technology and work methods evolve, it is important to regularly update and adapt protective systems to new requirements and threats.
- Recommendations for further research: Further research into new protective technologies and their effectiveness in various working conditions is necessary. These studies should also consider the specific needs of different industry sectors.
FAQ: Machine Run Study
Machine Run Study involves analyzing the time from the activation of the safety system to the complete stop of the machine. It is a key element in ensuring safety in industrial automation.
A Machine Run Study is crucial because it helps ensure that technical protective measures, such as light curtains and pressure-sensitive mats, are properly placed to prevent accidents and injuries.
The Machine Run Study is regulated by the ISO 13855:2010 standard, which defines the rules for placing technical protective measures concerning the approach speed of human body parts.
Typical technical protective measures include light curtains, laser scanners, pressure-sensitive mats, and two-hand control devices.
The Machine Run Study process includes:
Analyzing the approach speed of body parts.
Determining the total system stopping time.
Calculating minimum distances.
Implementing technical protective measures.
Yes, Machine Run Study is often necessary to obtain CE certification of machines and ensure compliance with Machinery Directive 2006/42/EC and Machinery Regulation 2023/1230.
A Machine Run Study affects machine design by ensuring that all safety systems are properly integrated and placed, minimizing the risk of accidents and injuries.
Challenges associated with a Machine Run Study include accurate calculations of minimum distances, regular reviews of protective systems, and adapting standards to specific working conditions.
Yes, outsourcing engineers specializing in production process automation and the Machine Run Study can be a beneficial solution for companies needing support in implementing advanced safety systems.
Benefits of a Machine Run Study include:
Increased employee safety.
Compliance with regulations and harmonized standards.
Reduction of accident and injury risk.
Improved operational efficiency through reliable protective systems.