Key takeaways:
The article discusses the role of machine guards in meeting safety and compliance requirements, including in the CE marking process. It presents the types of guards in accordance with EN ISO 14120 and the importance of design, audits, and risk assessment.
- Machine guards are essential for workplace safety in industry and industrial automation.
- The applicable legal requirements were identified: the Machinery Directive 2006/42/EC and the Machinery Regulation 2023/1230
- EN ISO 14120 describes the types of guards: fixed, movable, adjustable, and interlocking, and their applications
- Designing guards requires strength calculations (finite element analysis), ergonomics, and CAD and simulation tools
- Risk assessment in accordance with EN ISO 12100:2012 and regular audits verify the effectiveness of guards and support CE certification
Modern industry, especially industrial automation, places strong emphasis on workplace safety. A key element in ensuring safety is machine guarding, which must comply with a range of harmonized standards and regulations, such as the Machinery Directive 2006/42/EC and the Machinery Regulation 2023/1230. Implementing appropriate guards is also important in the CE certification process for machinery, which confirms that a machine meets all safety requirements.
Machine guarding in industrial automation
Industrial automation requires advanced technical solutions, including effective machine guarding. These guards must comply with harmonized standards to protect both operators and equipment. Compliance with the Machinery Directive 2006/42/EC is essential for the lawful use of machinery in Europe. In industrial automation, machine guards serve as the first line of defense against mechanical, chemical, and physical hazards that may arise during operation, alongside broader safety functions in industrial automation.
Machine guards in accordance with EN ISO 14120 – types
EN ISO 14120 defines various types of machine guards that can be used depending on specific needs and hazards. The most important of these are listed below:
Fixed guards
Fixed guards are permanently attached to the machine and can only be removed using tools. They are most commonly used where access to hazard zones is rarely required. These guards provide high durability and resistance to damage, which is essential in industrial environments.
Movable guards
Movable guards can be opened and closed without tools. They are fitted with interlocking systems that prevent the machine from operating when the guard is open. They are used where regular access to hazard zones is required, for example during maintenance or repairs. They provide easy access while maintaining a high level of safety.
Adjustable guards
Adjustable guards can be adapted to the size and shape of the material being processed. They provide the minimum opening needed to feed the material through while preventing access to hazard zones. They are particularly useful in production processes where material parameters change frequently.
Interlocked guards
Interlocked guards are equipped with monitoring systems that supervise guard status and prevent machine operation when the guard is not correctly positioned. They are used in the most critical applications, where safety is the top priority, for example in heavy industry, the FMCG industry, or automotive.
Table: Types of machine guards and their applications
| Guard type | Description | Application |
|---|---|---|
| Fixed guards | Permanently attached, removable only with tools | Hazard zones requiring infrequent access |
| Movable guards | Opened without tools, with interlocking systems | Regular access to hazard zones |
| Adjustable guards | Adapted to the size and shape of the material | Minimum opening, access to hazard zones |
| Interlocked guards | Monitored interlocking systems | Critical applications, highest safety requirements |
Machine guards: Design
Engineering design offices play a key role in machine guard design. This process requires accurate strength calculations (FEA) to ensure guard durability and reliability. Machine design in accordance with harmonized standards is essential for obtaining CE certification for machinery. During the design process, it is also important to consider ergonomics so that guards are easy to operate and maintain. Proper selection of protective measures should be preceded by hazard identification according to ISO 12100.
The use of modern design tools, such as advanced CAD software and FEA simulations, makes it possible to test guards thoroughly at the design stage. This helps avoid many potential problems that could arise during machine use.
CE certification for machinery and CE marking
The CE certification process for machinery includes assessing whether machine guards meet safety requirements. CE marking confirms that a machine complies with all applicable regulations and standards, which is essential for placing it on the European market. CE certification for machinery requires detailed analysis and testing to verify that guards effectively protect against mechanical and other hazards. In some cases, the conformity assessment process may also involve understanding the role of a CE notified body.
The CE mark is not only a symbol of regulatory compliance, but also evidence of quality and safety. It gives machine users confidence that a product meets the highest safety standards. The certification process includes both a review of the technical documentation and practical testing to confirm the effectiveness of guards under different operating conditions. It also covers product marking requirements, including the CE nameplate.
Safety audit and risk analysis
Regular safety audits and risk analysis according to EN ISO 12100 are essential for evaluating the effectiveness of machine guards. A safety audit helps identify potential hazards and implement corrective measures, improving workplace safety. Risk analysis includes assessing all possible hazards that may arise during machine use and defining actions to minimize them. In practice, this also requires risk assessment according to ISO 12100.
As part of a safety audit, all machine components, including guards, are inspected in detail. The audit checks whether the guards are installed correctly, whether they are damaged, and whether they meet all requirements of harmonized standards. Regular audits are crucial to maintaining a high level of safety throughout the machine’s service life.
Adapting machines to minimum requirements
Adapting machines to minimum requirements includes using suitable guards that meet safety standards. Examples include installing fixed and movable guards to prevent access to hazard zones. It is important that all guards comply with applicable standards and regulations, as this ensures their effectiveness.
Adapting machines to minimum requirements often involves upgrading existing equipment. These measures may include new guards, more advanced monitoring systems, and additional mechanical safeguards. All of these actions are intended to raise the level of safety and worker protection.
Harmonized standards and the Machinery Regulation 2023/1230
Harmonized standards define the technical requirements for machine guards, ensuring compliance with European regulations. The new rules introduced by the Machinery Regulation 2023/1230 raise safety standards by introducing additional requirements for guards. Implementing these standards and regulations is essential to ensure that machinery complies with legal requirements. These changes are particularly important for the machine manufacturer.
Harmonized standards cover a wide range of technical aspects, from the materials used to manufacture guards, through installation methods, to detailed requirements for strength testing. Compliance with these standards is not only mandatory, but also beneficial for manufacturers, enabling them to offer products of the highest quality. This is especially relevant in the case of particularly hazardous machines.
Project management and engineering outsourcing
Effective project management is essential for implementing machine guards in industry. Outsourcing engineers who specialize in the design and implementation of guards can significantly speed up the process while ensuring high quality and compliance with standards. Project management includes planning, progress monitoring, and quality control at every stage of project delivery.
Engineering outsourcing makes it possible to draw on the knowledge and experience of specialists with the right skills and tools to design advanced protective systems. This allows companies to focus on their core business while remaining confident that the design and implementation of machine guards are carried out to the highest standard.
Machine guards: Summary
Machine guards are an essential part of industrial safety. With proper design, certification, and regular safety audits, operators and equipment can be effectively protected against mechanical hazards. The future of machine guards is tied to continued technological development and higher safety standards, which will contribute to even better protection in industrial environments.
The introduction of advanced monitoring systems, innovative materials, and new technologies in machine guard design is the direction in which industry will continue to evolve. The use of these modern solutions will make it possible to protect hazard zones even more effectively, leading to improved safety and greater operational efficiency across various industrial sectors.
Machine guards – their importance in industry
Machine guards are the first line of protection against mechanical, chemical, and physical hazards during operation. They also help ensure compliance with regulatory requirements and harmonized standards.
The text identifies the Machinery Directive 2006/42/EC and the Machinery Regulation 2023/1230 as the key regulations. Compliance with them is essential for the lawful use of machinery in Europe.
EN ISO 14120 distinguishes, among others, fixed, movable, adjustable, and interlocked guards. Their selection depends on the process requirements and the level of risk in the given area.
Fixed guards are permanently secured and can be removed only with tools, so they are used where access is rarely needed. Movable guards can be opened without tools and are used where regular access is required; they are fitted with interlocking systems.
The CE certification process for machinery includes assessing guards for compliance with safety requirements, including documentation review and practical testing. CE marking confirms compliance with the applicable regulations and standards.