The evolution of global safety standards, the Impact of ever-evolving new technologies, and the desire to improve workplace safety records are major forces that continually drive improvements in integrated machine safety design.
What are some of the key future trends in machine safeguarding that significantly impact the machine and automation markets? What will be changing the shape and practices of the machine guarding industry? -5 Year Timeshare More Sophisticated Safety Controllers We will see the wider adoption and greater sophistication of safety controllers, which includes such devices as safety relay modules, relay-controller hybrids, safety Plus, and specific function safety controllers, such as a muting controller. The next step up in the quest for more intelligent safety controls are the relay-controller hybrids, often described as modular controllers. These are simple controllers with relay or electronic-based expansion modules.Programming can be as sophisticated as using PC-based software or as simple as using a screwdriver to set selector switches, pending on the system approach. These hybrids fill the gap between the safety relay modules and the more complex safety Plus.
These products are typically used in mid-range applications, or as subsets in more complex installations. For installations requiring more demanding programming needs, such as complex machine controllers and configurations, the trend Is to use safety-rated Plus.These devices contain the fall-safe software required for critical safety functions and can take direct Inputs from most safety products, such as light curtains. Emergency stops. ND mechanical interlocks.
From STIR"s perspective, our new safety light curtains and safety mat controllers are available with solid-state outputs. These outputs are very convenient and cost efficient, especially when the light curtain is connected directly to a safety-rated PL, thus eliminating the need for intervening safety relay modules. STIR"s Massage MAGGIE family of safety light curtains, shown here, offers an extremely wide range of detection capableness, from 14 mm finger detection to 50 mm arm detection. ) care Is needed to ensure that the safety PL system programming as been thoroughly reviewed and tested so no loss of safety function can result.
Users should not be able to alter this programming. The trend for safety Plus systems use will be in the mid-range to complex applications. Safety-Rated Buses and More Intelligent Safety Devices Another trend will be the evolving use of safety-rated communication buses or networks.The emergence of these safety control networks will have a major impact in the further integration of safety and machine controls into one seamless system.
The beauty of the safety-rated control network is that with less wiring, and hence much educed installation costs, a specific device can be identified and the problem diagnosed. With the use of a network cable, usually wired in series with the devices, the bus communications allow for the transfer of status and diagnostic Information, installation.The increased intelligence and diagnostic capability translates into less machine downtime and, therefore, higher productivity. (STIR"s 'MS Safety Muting System, shown here, easily integrates into nearly any entrance and exit conveyor system application, and is engineered to distinguish between material and people entering a dangerous area. All necessary components come in a single package, wired and assembled on a robust platform for easy installation and use. Safety networks have integrated the safety and control system as one common unit there is no need for a separate safety bus, or a separate safety PL.
A specialized bus safety controller or a PL outfitted with a safety control network module may be sufficient, depending on the complexity of the system and the number of devices. The use of a safety bus requires more intelligent safety devices with capabilities beyond the simple on/off or open/close outputs. Machine designers should expect the availability of these safety bus connection devices to grow.Safety devices such as interlock switches, emergency stop pushbuttons, and light curtains are available with the appropriate bus communications protocol and thereby provide improved diagnostics.
Greater Use of Machine-specific Safety Devices A trend that is Just emerging involves the design of a safety device for one specific type of machine. This is very different from a general-purpose safeguard, such as a light curtain, safety mat, or interlock. These products are readily used on many efferent types of machines, such as robots, mechanical power presses, lathes, mills, shears, etc.With this new trend, a device is machine specific, not machine independent. One such example are the new, moving ram type of optical safeguards specific to the hydraulic press brake, such as the Lasers from STIR (shown here).
Used for making precise bends in sheet metal, hydraulic press brakes are notoriously difficult to guard. By their very nature they are versatile machines, which may often require the operator to work close to the point of operation, depending on the size of he workplace and the type of bend required. Lasers"s optical transmitter and receiver mounts on the moving ram of the press.A 40 mm wide, flat band of laser light is projected under the tool tip to provide protection to the operator. Ram speed and stopping distance are continuously monitored by the Lasers controller through transducer feedback, maximizing the safety and throughput of the press brake and facilitating increased use of the high-speed mode of the press. The results are significant increases in productivity and enhanced safeguarding, clearly a win- in situation and not uncommon when safeguarding design can be optimized for a specific use.
0-15 Year Timeshare Intelligence: Devices will be able to act both on their own and in concert with one or more other controllers. We"al have distributed "intelligence" a bit of processing power and memory here, some more there, perhaps a large central chunk, each responsible for managing a small part of a process, but also tied in and coordinating with other "chunks" of processing power, working together to optimize the whole process (rather than the individual pieces). Networks: Networks will be critical to driving the "distribution" of processing power.We"al evolve from wired to wireless networks, virtually eliminating the need for Intelligence and Networking for Safety: From a safety perspective, light curtains might have a built-in controller and would be connected by wireless network directly to the motor, robot, gate, etc. Affected by their activity.
Safety Devices: More application-specific products such as Lasers will be developed, addressing very specific niches and needs in the safety market. Traditional safety devices such as safety light curtains, mats, interlocks, and relays ill continue to be used, supplemented and perhaps replaced in some applications, but not all.The devices will become smaller, less obtrusive, more easily designed, and more easily integrated into the machine it will be more and more the case that the safety device will be adapted to the machine design, rather than the machine design being adapted to the safety device. Diagnostic functions and displays will evolve, and troubleshooting will be simpler and more sophisticated for example, a factory representative might remotely connect to and diagnose a device, and be able to tell the customer how to fix the specific problem.
