Smart Safety - Rockwell Automation

Smart Safetyn Increase productivityn Minimise downtime with diagnosticinformation from the safety systemn Benefit from the broadest portfolio of safetyproducts, solutions and servicesn Enable smarter machines for use inThe Connected Enterprise

Smart Safety – enabling smartermachines and equipmentHarnessing the power of safety and operational data cansubstantially improve safety compliance and performance.Accessing safety system data and transforming it intomeaningful information results in increased machineryproductivity, and minimises downtime.To gain more diagnostic data traditional safety devicesrequired more complex wiring solutions. With a SmartSafety solution, you can now access more diagnosticdata and simplify your wiring system.An integrated Smart Safety solution provides all thedata needed to create a comprehensive picture of thestatus of the machine or production line.Challenges to safe operationsWorker behaviours¡¡ Operators bypassingpoorly designedsafety systems¡¡¡¡Systems that don’taccount forprocedural anomaliesStandard operatingprocedures notbeing followedEvolving workforce¡¡ Safety implications ofmajor workforceshift worldwide¡¡¡¡Older workersnearing retirementat higher risk formusculoskeletal injuriesMachinery downtime¡¡ Downtime for jams,misfeeds, adjustments,changeovers andmaintenance¡¡Minimal visibility ofdowntime information¡¡No context of downtimeissues (workersinteraction, machineryfault, shift patterns)Younger, lessexperienced workersmore prone to injury¡¡Limited information toremedy issuesRegulatory complianceCompliance withindustry standardscan be challengingData management¡¡ Continuing reliance onoutdated data collectionand reporting methods¡¡ Documenting and¡¡Safety data oftenmanually entered forinspections, compliancelogs, incident reports,training andother processes¡¡Systems in which datais stored typically notconnected to plantfloor systems¡¡reporting on approvedsafety systems canbe challengingSmart Safety2

Access to real-time data and seamless connectivity is transformingthe production environment. Smart capabilities enable end users togain new efficiencies, improve product quality and make operationsmore responsive. Smart Safety helps to standardise machineryand safety control. These systems are less susceptible to nuisanceshutdowns and can help to improve productivity and profitability.Why is the E-stop functionbeing operated so much?PALLETIZER ACCESSLOW MARGINRequests in 24hrsPer week0 0 0 90 0 0 2Number of operations monitoredfor replacement scheduling.!SAFE SPEED ACTIVATIONOBJECT DETECTED.Low Margin!Average times per hourCleaning requiredDAMAGED SWITCH0 0 0 2! ! ! !!Damaged Switch!Zone 1, Conveyor!EMERGENCY STOPSTimes tripped per day0 0 2 0!Misalignment!Line 1, guard door 3!LIGHT CURTAINTimes tripped per day0 0 1 0Smart Safety3

Smart Safety devicesSmart Safety solutions provide detailed diagnostic data to yourdesign environment, visualisation system, information software,and GuardLogix Programmable Automation Controller –enabling Smart Machines for use in The Connected Enterpriseand helping to increase productivity and minimise downtimewhile reducing total cost of ownership.VisualisationThe Connected Enterprise/Industry 4.0Information SoftwareDesign EnvironmentEtherNet/IPInputLogix Programmable Automation ControllerEtherNet/IPLogicOutputSafety over GuardLink(up to PLe SIL3)EmergencystopNon contactswitchesGuard lockingswitchesBenefits of Smart SafetySafety over EtherNet/IP(up to PLe SIL3)Key InterlockSwitchesCable pullswitchesMultifunctionalAccess BoxLightCurtainsSafetyScannerCable reduction of up to 38%Smart Safety4

Smart Safety enables Smart Machinesfor use in The Connected EnterpriseA solution incorporating Smart Safety devices enables safety professionals to transformthe way they monitor and manage safety. Rockwell Automation provides a completeSmart Safety solution to meet safety requirements, covering safety input devices, safetylogic and safety output UTIONSI N T E G R AT E D S A F E T Y S O L U T I O N SSAFETY INPUTSSAFETY LOGICCONTROLLERSSAFETY OUTPUTSCONNECTION SYSTEMSDESIGNTOOLSLEGISLATION& STANDARDSGUIDANCESAFETYSERVICESImprove insight into worker behaviour and complianceBy incorporating safety information into EHS management systems, day to daydiscrepancies between policies and operating procedures can be identifiedEnhance safetyConnecting people, equipment and worksites creates new opportunities toenhance worker and environmental safety, including remote access, operationsvisibility, worker locating and information delivery via mobile devices.Reduce safety-related downtimeBetter visibility into safety-system performance and stoppages can helpdetermine the root cause of shutdowns. Safety and production data also canbe combined to understand the frequency, duration, time and location ofsafety-related shutdowns.Improve complianceThe safety data required for compliance and reporting purposes is largelycollected through time-consuming, error-prone manual audits today. Byintegrating auditing functions into the HMI and controller, organisations canautomate and speed up the auditing process, free up personnel to focus onother priorities, and reduce the likelihood of errors.Smart Safety5

Scenario 1Remotetroubleshooting withSmart SafetySafety device performance communicatedover EtherNet/IP¡¡ Predictive maintenance routines established fromhistorical data¡¡ EtherNet/IP network allows standard and safety datato be captured on individual device operation¡¡ Simplifies wiring and system complexity¡¡ All time stamped data of device operation availablein FactoryTalk Historian11. Light curtain has buildup of dirt reducing sensing field.22. Machine operator quickly informed whichlight curtain has an issue.¡¡33. Machine operator cleans the light curtain,preventing unnecessary machine downtime.55. All device interactions are captured in system.Data can be used for predictive maintenance plans.44. All smart devices on the machine give current statusinformation to operator, where and when it is needed.66. Machine working efficiently and with predictivemaintenance planned.Visit www.machinesafetysolutions.com to see how Smart Safety can make the differenceSmart Safety6

Scenario 2Request safeaccess overEtherNet/IP networkGuard position, lock status and access requestmanaged over standard unmodified ethernet(Safety over EtherNet/IP)¡¡ Historical data of access request can be used forapplication adjustments¡¡ Simplified network architecture for standardand safety control¡¡ Add-on profile in Studio 5000 provides simplifiedsetup and monitoring¡¡ Indication given separately for guard door positionand guard lock status11. Box falls from pallet in shrink wrapper due tospeed of conveyor.22. Machine operator requests safe access via smart safetyinterlock device. Request action logged in system.¡¡33. System checks for safe condition and then grantsaccess. Access approval logged in system.55. Machine operator closes guard door, initiates areset request which locks the guard closed.Request logged in system.44. Machine operator safely enters machine andreplaces fallen box.66. All data logged in system is available to enablemachine performance adjustments.Visit www.machinesafetysolutions.com to see how Smart Safety can make the differenceSmart Safety7

Scenario 31Machine uptime fromSmart Safety dataAccess frequency into the machine through individuallyidentified access points, is available with Smart Safety¡¡ Smart Safety allows data to be capturedon individual device operation¡¡ Simplifies wiring and system complexity¡¡ Smart Safety can be used with yourexisting safety devices¡¡ Historical data of access request can be used forapplication adjustments¡¡231. Tape from supplier frequently breaking.33. Machine operator restarts machine.55. Production manager and machine operator discuss reasonof frequent access. Tape causing problem can be replaced.2. Machine operator opens interlocked guard doorto fix tape. Device operation is logged in system.44. Production manager has all data available onsafety device actions.66. Machine running more efficiently with lessmaintenance required.Visit www.machinesafetysolutions.com to see how Smart Safety can make the differenceSmart Safety8

Scenario 4Predictive maintenancewith Smart SafetysolutionSmart Safety allows predictive maintenance proceduresto be adopted based on device use or age¡¡ Smart Safety allows data to be captured on individualdevice operation¡¡ Simplifies wiring and system complexity¡¡ Smart Safety can be used with your existing safety devices¡¡ Historical data of access request can be used forapplication adjustments11. Operations of safety devices per shift are captured.22. All safety device operational use frommanufacturing line available.¡¡33. Monitoring number of operations helps predictwhen device is at end of life.55. Device can be replaced at next plannedmaintenance schedule.44. Information is available for maintenance staffto replace device.66. Machine downtime reduced to a minimum.Visit www.machinesafetysolutions.com to see how Smart Safety can make the differenceSmart Safety9

3 pillars of support for your safety requirementsThe right productsThe right toolsRockwell Automation has the broadest portfolio of any machinery safety solutions supplier,and can provide all three parts of a safety system.A wide range of tools that support compliance with safety standards, reduce the risk ofinjuries and improve productivity.Safety input devicesSafety actuatorsSafety Automation Builder Presence-sensing safety devices Safety interlock switches Emergency stop & trip devices Operator interface Safety contactors PowerFlex AC drives Kinetix integrated motionFREE software tool to help simplify machine safety design and validation, reducing timeand costs. Integration with RASWin Risk Assessment Software provides you with consistent,reliable, documented management of the Functional Safety Lifecycle.Connection systems/networksSISTEMA integrationSafety logic controllers Safety relays Configurable safety relay Integrated safety controllers Safety I/O devices ‘Quick connect’ connection systems Safety over EtherNet/IP GuardLink linking technologyThe SISTEMA tool automates calculation of the attained Performance Level outlined in(EN) ISO 13849-1. Data is available to be used with the SISTEMA calculation tool. Helps users in the design stage Comprehensive Rockwell Automation databasePre-engineered Safety FunctionsMachine safety can be developed by combining blocks of safety functions. Our preengineered safety functions come with a SISTEMA Performance Level calculation asoutlined in (EN) ISO 13849-1. Reduces design times Includes set-up, wiring, configuration and validation information Complete bill of materialsAccelerator ToolkitsEasy to use system design, programming, and diagnostic tools to assist in the rapiddevelopment and deployment of safety systems. Reduces design time and riskSmart Safety10