Download document () of 20

Integrating functional safety in machines

Safety for machines and systems
 
Software SISTEMA
 
Safety-related characteristics
 

Switch off and work safely

Functional safety is an essential part of the design process for machines because it is key to protecting the wellbeing of the machine operator and keeping production up and running. To ensure functional safety, the latest guidelines have to be applied - design guidelines with standardized and accepted circuits can help to notably reduce implementation efforts.

For more than ten years, DIN EN 60204-1 has ensured the safe design of electrical equipment for machines and plants. The underlying IEC 60204-1 standard was updated in 2016 - now the European version of the world's most widely used machine safety standard is published. This whitepaper provides an overview of the most important changes for machine and plant manufacturers, especially with regards to switchgear technology.

 

eaton-functional-safety-eu-directives-and-standards-graphic-en-us.jpg

Internationally harmonized regulations, known as EU Directives, are in place to ensure balanced protections for people and the environment and to reduce competitive disadvantages and hurdles to business due to different safety regulations within the EU. 

The safety of machines is primarily covered within two directives. The Machinery Safety Directive is oriented toward producers of machines, while the Work Equipment Directive is oriented toward operators of machines. A principle known as the 'Presumption of Conformity' applies to the fulfillment of requirements defined in harmonized standards. It presumes that the protective goals of the EU directive are to be regarded as sufficiently met.

Our safety manual gives you an overview of the most important directives, standards and regulations for machines in the EU.

Find out how you can control the unexpected in our safety manual

Safety manual

The Eaton Safety Manual provides an easy entry-level into the extensive set of material available on safety technology. The manual contains an overview of the most important factors of directives, standards and regulations that have to be taken into consideration when using safety equipment on machines.

Software SISTEMA - Safety of controls on machines - simple to calculate

The manufacturer-independent calculation tool SISTEMA from the Institute for Occupational Safety and Health of the German Social Accident Insurances (IFA) provides assistance in the evaluation of safety-related control components in the context of EN ISO 13849-1 and simplifies risk assessment analysis.

Selection of the design structure of the protective devices and the assignment to an architecture compliant to the EN ISO 13849-1 is implemented in a Windows user interface. 

On this basis, the software calculates the reliability values as well as the attained Performance Level (PL).
A direct comparison with the required Performance Level (PLr) is thus possible.

The software records the relevant parameters for evaluation such as MTTFd, B10d, DCavg and CCF. It directly indicates the influence of variable parameters on the overall result.

Further information and the SISTEMA software download can be found directly at the IFA.

eaton-sistema-software-calculation-safety.jpg

Libraries for SISTEMA

The software assistant SISTEMA provides the opportunity to load the technical safety-related parameters of components into the program from an existing library. Design engineers have the manufacturer’s data directly available in the software. Manual data entry is not necessary. Eaton provides the libraries for integration into the SISTEMA software at: Input, Logic or Output. Please note that the libraries are updated on an ongoing basis and new products are continuously added.

Input

eaton-safety-management-sistema-input.jpg

Logic

eaton-safety-management-sistema-logic.jpg

Output

eaton-safety-management-sistema-output.jpg

Universal Database for VDMA 66413 Parameters

The as per 2006/42/EC Machinery Safety Directive harmonized standards EN IS 13849-1, EN ISO 13849-2 and EN 62061 require evaluations and calculations relating to the likelihood of a dangerous failure and systematic aspects of a machine's safety functions. Eaton offers the database of its own logic components for all manufacturer-specific calculation tools with a VDMA 66413 import interface in English and in German (ESR5 and ES4P range of products). Each device description (IL) and one photo are also an integral part of the database. Thus,the project manager has the manufacturer's values available directly in the software. Manual data entry is not necessary.

Implementing functionally safe circuits with the right products

Emergency stop push buttons for various applications
Emergency stop push buttons for various applications
Emergency stop pushbutton RMQ compact Series  with cable and M12 plug
Emergency stop pushbutton RMQ Compact Series with cable and M12 plug
Safety contactors with non detachable auxilary switch identified by yellow cover
Safety contactors with non detachable auxilary switch identified by yellow cover
Safety logic, safety relay, safety logic relay
Safety logic like safety relay and safety logic relay
Safety positioning switches and safe non contact switches
Safety positioning switches and safe non contact switches
eaton rotary cam switches shafts handles accessories
Switch disconnectors

Safety-related characteristics

Functional safety includes calculation and documentation of the likelihood of failure for the individual safety functions. As a manufacturer of machines and equipment, additional characteristic values are required for safety-oriented products. The safety characteristic values are made available by the manufacturers of the products. These values are used together with statistical calculation tools to determine the attained safety level, known as a performance level in EN ISO 13849-1 or the Safety Integrity Level in IEC 62061 and IEC 61508.

Eaton provides you with all the specific characteristic values for safety-relevant components in the following download.

Reliability values to EN ISO 13849-1:

  • B10d: Number of operations until 10% of the tested components fail dangerously
  • MTTFd: Mean Time To dangerous Failure. Average of the time expected up to a dangerous failure
  • PL: Performance Level

Reliability values to IEC 62061:

  • B10: Number of operations until 10% of the tested components fail
  • PFHd: Probability of dangerous Failure per Hour
  • SIL CL: Safety Integrity Level Claim Limit