Functional Safety of Machinery

• Introduction “TÜV Rheinland Functional Safety Training Program“
• Machine Directive, A, B and C standards.
• Standards and status of standards regarding Functional Safety in Machine safeguarding.
• Basic concepts of European Guidelines (Machinery Directive/Regulation and CE Marking)
• Importance (meaning) of harmonized and non-harmonized standards.
• Machines and safety components listed in the appendix IV of the Machinery Directive.

Risk Analysis

• Methods for determination of necessary measures for the reduction of risks at machines (ISO 12100).
• Hazards & Risks
• 3-Steps Risk Reduction Strategy - Direct, indirect, and indicative safety.
• Proof and Documentation
• Safety Function Definition
• Procedure acc. to ISO 13849 and EN 62061
• Risk Matrix & Risk Graph
• Required PL & SIL Calculations
• Examples.
• Comparison of safety classifications

Introduction to ISO 13849

• Importance (meaning) of safety categories.
• Control Categories
• Basic safety principles, well-tried safety principles and well-tried components
• Principal information regarding deterministic fault consideration, faults, and fault exclusions acc. to ISO 13849-2.

Safety Devices

• Systematic of safety devices, advantages and disadvantages, installation requirements, configuration of safety devices.
• Types of Protective Equipment for Machinery (Separating and Non-Separating Guards)
• Interlocking, Guarding Locking, Position Switches, Proximity Switches, ESPEs, AOPDs, AOPDDRs, Mats, Edges, Bumpers, Two-Hand Controls, Enabling Devices,
• Guards, interlocking devices:
  • Types, examples regarding application, installation requirements acc. to different safety categories
  • Circuit Examples
  • Faults, fault exclusions.
  • Normative requirements.
• Other safety devices:
  • Type, installation requirements, advantages, and disadvantages.
  • Calculation of safety distances.

Safety functions of machines

• Power-Drive Systems
• Start/re-start interlock, start functions, reset.
• Hold-to-Run controls.
• Emergency off, emergency switching off, stop categories, muting etc.
• Realization acc. to the different safety categories
• Stop Functions
• Other Safety Functions

Circuits, schematics, examples

• Connection of safety devices to controls, interface circuits.
• Realization acc. to the different safety categories.
• Examples for correct and incorrect typical circuits.

New standards regarding safety of machinery

• Importance (meaning) of these standards regarding quality management, documentation and safety related availability.

ISO 13849

• Contents of ISO 13849-1, application area, restrictions regarding applicability.
• Designated Architectures (Categories)
• Failure Probability (MTTFd, B10d, T10d)
• Failure Probability (DC)
• Failure Probability (CCF)
• Failure Probability (PL Calculations)
• Documentation requirements and quality management.
• Requirements regarding Software.
• Random and Systematic Failures
• Use of standard components in safety functions.
• Proof of safety, verification, and validation of safety functions.
• Examples.

Validation

• Validation acc. to ISO 13849-2.

Examples

• Examples for proof of Functional Safety acc. to ISO 13849-1.

IEC 62061

• Content of IEC 62061, application area.
• Design process
• SRS – Safety Requirements Specification
• Documentation requirements and quality management, life cycle model.
• Meaning of terms SIL, SIL CL, HFT, SFF and their context.
• Subsystems Architectures
• Requirements regarding safety relevant application software.
• Proof of safety, verification, and validation of safety functions.

Examples

• Examples for proof of Functional Safety acc. to IEC 62061.

• Exam