Synergy Automatics are one of the trusted Special Purpose Machine manufacturers in Chennai, delivering innovative and safe automation solutions for diverse industrial applications. When designing SPMs, safety compliance and risk assessment are critical for operator protection and system reliability. Below is a detailed guide on international standards, safety frameworks, and risk management practices for SPM design and operation.
1. Standards & Risk Assessment
- Risk Analysis Frameworks:
- ISO 12100: Identify hazards across operational phases—loading, cycling, maintenance.
- ISO 14121: Apply hazard severity × exposure frequency × avoidance possibility.
- Functional Safety Control:
- Use ISO 13849-1 or IEC 62061 to define safety integrity levels (PL or SIL).
- Implement dual-channel safety PLCs or relays for E-stops, light curtains, etc.
2. Physical & Functional Safeguards
- Fixed & Interlocked Guards:
- Comply with ISO 14120 for guard strength and secure mounting.
- Ensure interlocks cut power to dangerous motion before access is granted.
- Presence Detection:
- Install light curtains, safety mats, and area scanners on load/unload zones.
- Devices must connect to safety relays with fault detection and auto-reset logic.
- Emergency Stops (ISO 13850):
- Mushroom-head pushbuttons at every operator station and hazard point.
- Confirm Category 3 or 4 fault tolerance in wiring with feedback to safety controller.
3. Control-System Safety Logic
- Safe Stop Categories:
- Cat 0: Instant power off (e.g., cutter ejection).
- Cat 1: Controlled stop before power cut (e.g., flywheel deceleration).
- Motion Safeguards:
- Use two-hand controls, enabling switches, or hold-to-run joggers for setup mode.
- Integrate speed monitoring to reduce movement speed in teach or access zones.
4. Electrical, Pneumatic & Hydraulic Safety
- Electrical Panel Compliance:
- IEC 60204-1 standards: grounding, overload protection, labeled terminals.
- Panel-door interlocks must trigger automatic safe-stop when opened.
- Pneumatics & Lockout:
- LOTO-compatible valves with pressure-bleed indicators.
- Emergency shutoffs for air/hydraulic supply, tagged and accessible.
5. Ergonomics & Operator Access
- Ergonomic Layout:
- Maintain ≥500 mm safe clearance zones around manual workstations.
- Place HMI at 1300–1500 mm height; ensure controls are within natural reach.
- Handling Support:
- Vacuum grippers, lift-assist arms, or roller conveyors for heavy loads.
- Lighting:
- ≥300 lux in active zones with diffused, glare-free lighting.
6. Training & Procedure Control
- Operator Certification:
- Mandatory onboarding for machine operation and E-stop reset protocols.
- Annual refreshers + skill assessments logged by HR/safety manager.
- Safe Work Permits:
- Documented checklists for die changes, tooling swap-outs, off-cycle tasks.
- Permit includes pre-operation checklist, isolation steps, and supervisor sign-off.
7. Testing & Validation
- Pre-Commissioning Safety Testing:
- Validate all circuits, guards, and devices under simulated faults.
- Log test results per ISO 13849-2 requirements.
- FAT & SAT Audits:
- Factory and Site Acceptance Tests should include real-condition operation with operator training.
8. Maintenance & Lifecycle Safety
- Scheduled Inspections:
- Daily: Guards, E-stop test, sensor response.
- Monthly: Relay contact resistance, actuator travel checks.
- Incident Investigation:
- All E-stop activations or interlock bypasses logged and analyzed.
- “5 Why” root cause + corrective actions tracked for audit trails.
- Ongoing Risk Review:
- New tooling or control logic requires full safety re-validation and risk reassessment.