Machinery design safety is a crucial aspect of manufacturing engineering, as it affects the performance, reliability, and well-being of both the machines and the operators. In this article, you will learn some of the best practices and principles for ensuring machinery design safety, from the initial concept to the final testing and maintenance.
The first step in machinery design safety is to identify the potential hazards and risks that the machine may pose to the users, the environment, and itself. Hazards are any sources of harm or damage, such as sharp edges, moving parts, electrical currents, or high temperatures. Risks are the likelihood and severity of the harm or damage occurring. You can use tools such as hazard identification checklists, risk matrices, or fault tree analysis to systematically assess the hazards and risks of your machine.
Ensuring machine design safety involves rigorous risk assessment, adherence to safety standards, and implementation of protective measures such as emergency stops, safety guards, and fail-safe systems. Regular maintenance and operator training are also crucial to maintain a safe working environment.
Risk analysis in Industrial Robots for manufacturing projects are very crucial. Movement of robotic arm, posing the risk of physical injury to nearby workers and machinery. Using a hazard identification checklist or fault tree analysis to identify contributing factors like Robot programming errors, sensor malfunctions, lack of training, fencing, guards, covers.
The next step is to apply design principles that aim to eliminate or reduce the hazards and risks of your machine. Inherently safe design is one approach, which involves designing the machine in such a way that it does not create any hazards or risks in the first place, or minimizes them as much as possible. Safety by protection is another approach, which entails designing the machine with protective features that prevent or limit exposure to the hazards or risks. For instance, guards, shields, barriers, and interlocks can be used to isolate or block dangerous parts of the machine. Finally, safety by information is a design principle that incorporates informative features that warn or instruct users or the environment about hazards and risks, and how to avoid them. This could be done through labels, signs, indicators, alarms, and manuals.
The third step is to follow the relevant standards and regulations that apply to your machine and your industry. Standards and regulations are sets of rules and guidelines that specify the minimum requirements and best practices for machinery design safety. They are based on scientific, technical, and legal knowledge and experience. They help you to ensure that your machine meets the expectations and needs of the customers, the authorities, and the society. You can find standards and regulations from various sources, such as national or international organizations, industry associations, or professional bodies.
For CNC machines, ISO 13849 standard is often applicable. ISO 13849 outlines safety requirements for the design and integration of safety-related control systems, including those used in CNC machinery. ISO 10218 pertains to the safety of industrial robots, including CNC-controlled robotic systems. Additionally, standards like ISO 16090-1 provide guidelines specific to the safety of machining centers.
The fourth step is to test and evaluate your machine before and after it is put into operation. Testing and evaluation are processes of verifying and validating that your machine performs as intended and meets the safety criteria and specifications. You can use methods such as simulations, prototypes, inspections, audits, or feedback to test and evaluate your machine. Testing and evaluation help you to identify and correct any errors, defects, or deviations that may compromise the safety of your machine.
In CNC machine safety, testing and evaluation can be done by simulating and assessing the machine's programmed movements for any unexpected behaviors. Checks for safety interlocks, emergency stop buttons and protective barriers, function correctly. Inspections and audits verify compliance with ISO 13849 and ISO 10218 safety standards, covering control systems and robotic elements. Continuous feedback from operators and maintenance teams during trials will help to identify and rectify any safety concerns.
The final step is to maintain and improve your machine throughout its lifecycle. Maintenance and improvement are activities of keeping your machine in good condition and enhancing its safety performance. You can use techniques such as preventive maintenance, corrective maintenance, or continuous improvement to maintain and improve your machine. Maintenance and improvement help you to prevent or resolve any issues, failures, or accidents that may affect the safety of your machine.