CMAFH Drive For Technology New Safety Standards / Machinery Directive

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1 New Safety Standards / Machinery Directive CMAFH Drive For Technology 2012 New Safety Standards / Machinery Directive Gary Thrall Senior Product Support Engineer Bosch Rexroth Corporation updated 1

2 New Safety Standards / Machinery Directive New European Standards status update European Machinery Directive extension of EN expired IEC Performance Level 10 steps IEC Functional safety for speed variable drives 2

3 Machinery Safety 3

4 Passport into European Community market (EEA) European Machinery Directive Machine Builder EC Fulfilling harmonized standards the manufacturer can assume that the safety aspects of the machine directive are met EN (EN 954-1) EN EN

5 EN Extension for Machinery Directive EN954-1 was prolonged until December 31, 2011 but has now expired Why? European companies were encountering difficulties U.S. companies struggled to understand the requirements of the new ISO standard Are we ready now? By integrating safety application requirements into certified firmware and software, numerous electromechanical components are no longer needed, safety is enhanced, and profits are increased. This approach to safety compliance simplifies the application for the OEM and can generate more machine uptime for the end user. 5

6 Change of Standards Today Machine Builder European Machinery Directive 98/37/EG EN Valid Standard Period 3 years EN ISO Transition November 2006 EN January /42/EG January 2010 Extended 2 more years Transition Valid Standard December 2009 Valid Standard Components EN IEC November 2007 Valid Standard Valid Standard 6

7 Performance Level of EN ISO :2006 The Performance Level is defined by Category (architecture), identical to EN and C-Standards MTTF d (Meantime to dangerous failure in one channel) Denotation of MTTF d Low Medium High Range of MTTF d 3 years <= MTTF d < 10 years 10 years <= MTTF d < 30 years 30 years <= MTTF d < 100 years DC (Diagnostic Coverage): Share of detected failures Denotation of DC None Low Medium High Range of DC DC < 60% 60% <= DC < 90% 90% <= DC < 99% 99% <= DC CCF (Common Cause Failures affecting both channels) Measures against systematic failures 7

8 10 Steps to Performance Level Step 1 8

9 10 Steps to Performance Level Step 1 9

10 10 Steps to Performance Level Step 3 10

11 10 Steps to Performance Level Step 4 11

12 10 Steps to Performance Level Step 5a 12

13 10 Steps to Performance Level Step 5b 13

14 10 Steps to Performance Level Step 6 14

15 10 Steps to Performance Level Step 7 15

16 10 Steps to Performance Level Step 8 16

17 10 Steps to Performance Level Step 9 17

18 10 Steps to Performance Level Step 10 18

19 Functional Safety Terms and Parameters 19

20 Performance Level of EN ISO :2006 A Performance Level d could be achieved by: Cat. 3 Cat. 2 DC avg = medium or DC avg. = medium MTTF d = medium MTTF d = high 20

21 EN and EN Safety Integrity Level SIL IEC Probability of dangerous failure per hour (1/h) PFH d Performance Level PL ISO IEC >= 10-5 to 10-4 a 1 >= 3 x 10-6 to 10-5 b 1 >= 10-6 to 3 x 10-6 c 2 >= 10-7 to 10-6 d 3 >= 10-8 to 10-7 e 4 < ISO electrical, electronic and programmable calculation formula for subsystem architectures All Technologies Simplified Estimation (worst case) regarding to: HW Structure (Category like EN 954) Diagnostic Coverage (DC) Reliability MTTF d Failure of Common Cause (CC) PFH d Probability of a dangerous Failure per Hour 21

22 Performance Level in total Performance Level of the combination of SRP/CS SRP/CS 1 PL 1 Cat 3 SRP/CS 2 PL 2 Cat 3 SRP/CS 3 PL 3 Cat 3 SRP/CS 4 SRP/CS PL 4 5 SRP/CS PL 5 6 SRP/CS PL 6 7 SRP/CS PL 7 8 SRP/CS PL 8 9 PL 9 PFH total = PFH Sensor + PFH IO + PFH SafetyPLC + n x PFH Drive Cat 3 PFH total = 2, , , x 4, PFH total = 5, < > PL d EN ISO :2006 Category 3 PL d 22

23 SafeMotion Safe Torque Off (L2): EN ISO :2006 Category 3 PL = e IEC EN 62061:2005 EN :2007 SIL3 PFH d = 2 * /h MTTF d = 100 years (limitation by standard) Mission Time = 20 years The PFH values are based on a 100% duty cycle (24h/ 365 days) 23

24 SafeMotion Safe Motion (S2): EN ISO :2006 Category 3 PL = d IEC EN 62061:2005 EN :2007 SIL2 PFH d Drive = 3 * /h PFH d Feedback = 2 * /h (Stegmann/ Heidenhain motor feedback) MTTF d = 100 years (limitation by standard) Mission Time = 20 years To calculate the MTTF d value for a drive and feedback combination: Add the PFH values and convert then into a MTTF d value. Do not add the MTTF d values since they are limited to 100 years. The PFH values are based on a 100% duty cycle (24h/ 365 days) 24

25 SafeMotion Safety Integrity Level SIL IEC Probability of dangerous failure per hour (1/h) PFH d Performance Level PL ISO IEC >= 10-5 to 10-4 a 1 >= 3 x 10-6 to 10-5 b 1 >= 10-6 to 3 x 10-6 c 2 >= 10-7 to 10-6 d 3 >= 10-8 to 10-7 e 4 < ISO ( note that 10 8 hours is 11,415 years) Preliminary Data for IndraDrive, Safety on Board Safe Torque Off: PFH d = 2 * /h = 2 % of max. SIL3 value Safe Motion: PFH d Drive and feedback = 5 * /h = 5 % of max. SIL2 value 25

26 IEC New Terminology (not all available) EN : 2007 Functional safety for speed variable drives Safe Torque Off STO Safe Stop 1 SS1 Safe Stop 2 SS2 Safe Operating Stop SOS Safely-monitored Deceleration SMD 1) Safely-limited Acceleration SLA Safe Acceleration Range SAR Safely-limited Speed SLS Safe Speed Range SSR Safe Speed Monitor SSM Safe Maximum Speed SMS 1) Safely-limited Increment Safe Direction Safely-limited Position SLI SDI SLP Safely-monitored Position SMP 1 ) Safe Brake Control SBC Safe Braking and Holding System SBS 1) Safely-limited Torque Safe Torque Range Safe Motor Temperature Safe Cam SLT STR SMT SCA 1) Not defined in IEC

27 Drive Based Safety Functions Safe Torque Off (STO) v Safe Torque off (Stop Category 0*) t 0 t Drive is torque-less Power is cut safely (pulse inhibit) * according to EN

28 Drive Based Safety Functions Safe Stop 1 (SS1) / Safe Stop 2 (SS2) v Controlled Stopping according to stop category 1* (SS1) monitored stopping, control or drive controlled with safe deceleration t 0 t 1 t Torque-less standstill of the drives Power is cut safely (STO) Controlled Stopping according to stop category 2* (SS2) v, s t 0 t 1 t monitored stopping, control or drive controlled controlled standstill after stopping, no power off (SOS) * according to EN

29 Drive Based Safety Functions Safely Limited Speed (SLS) / Safely Limited Increment (SLI) v Within the Safe Mode a safely limited speed and / or a safely limited increment can be enabled (enabling device) t 0 t 1 t 30 v, s v, s t In case the speed/increment monitoring window will be triggered the drive will be safely stopped automatically in accordance with the stop category 1. 29

30 Drive Based Safety Functions Safe Direction (SDI) v In addition a safe direction (right, left) can be defined. 0 t In case the direction changes the drive will be safely stopped automatically in accordance with the stop category 1. 30

31 Drive Based Safety Functions Safe Maximum Speed (SMS 1 ) v Max The monitoring of a safely limited maximum speed is active always, regardless the operation mode of the drive (Automatic/Manual Mode) 120 t In case the parameterized maximum speed will be exceeded the drive will be safely stopped automatically in accordance with the stop category 1. 1) Not defined in IEC

32 Drive Based Safety Functions Safely Monitored Position (SMP 1 ) Working Area Position 1 Position 2 In the safe operation mode a working area (absolute position) can be defined In case the parameterized working area will be left, the drive will be safely stopped automatically in accordance with the stop category 1. 1) Not defined in IEC

33 Drive Based Safety Functions Safely Limited Position (SLP) active in normal and safe operation mode - The drive is not able to cross the limited switches - The drive is stopped automatically when the available deceleration torque would not be sufficient to stop the load before the parameterized position area will be left Offers cost saving by replacing hardware position limit switch v v max Max. Positive Limit Switch Max. deceleration deceleration s Negative Limit Switch 33

34 Safety on Board SafeMotion - More than just Switching Off! The evolution of safety technology Safety reaction Switching off Safety condition SafeMotion 34

35 Additional Resources for downloadable manuals including Safety on Board Application Manual or just Google IFA SISTEMA for BGIA software to calculate PFHd and Performance Level to IEC steps to performance level Handbook for the implementation of functional safety according to ISO Available in English next week. Bosch Rexroth Safety on Board hands-on workshop next scheduled for May 15th and 16th in Hoffman Estates (more to follow) 35

36 New safety standards / Machinery Directive Thank you for your attention! 36