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Safety Components
Risk and Safety Category Assessments,Interlocking Devices,Basic Safety Functions in the Event of a Fault,Presence Detection,Two-hand Controller,Functional Safety Technology,
Applications
2. Interlocking Devices
3. Basic Safety Functions in the Event of a Fault
4. Presence Detection
5. Two-hand Controller
6. Enabling Switches
Safety Functions
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The responsible machine or process designer no longer considers the production requirements and adds safety systems later,
but addresses the two
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standards and regulations - it is a legal requirement.
Different types of machines will have different levels of associated risk. These risk levels need to be addressed for the whole
machine life span. In particular the requirements at commissioning, application/usage and decommissioning of the machine
must be considered.
Risk assessment according to ISO14121 is a series of logical steps that enables designers and safety engineers to examine in
a systematic way the hazards arising from the use of machinery so that appropriate safety measures can be selected.
Defining machine limits requires the following points to be considered when assessing risk.
Determining requirements for all phases of the machine's life
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Defining the intended use and operation and the foreseeable misuse and malfunction
DefiningOmron uses cookies
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physical ✕
abilities (e.g., impaired eyesight or hearing, size, and strength)
Expected user training, experience, and competence
Possibility that people may be exposed to machine hazards
Possibility that people may be exposed to machine hazards if a foreseeable machine hazard occurs
Hazard identification means checking for all the hazardous conditions and hazardous events associated with the machine. This
involves predicting hazards that may be caused by the machine, such as the following:
Mechanical hazards: Severing, entanglement, crushing, etc.
Electrical hazards: Contact with live parts, static electricity, etc.
Thermal hazards: Health disorders due to contact with high-temperature parts or working in a high-temperature or low-
temperature environment
Methods for clarifying hazards include the following:
Check lists
Hazard and Operability Study (HAZOP)
Failure Mode and Effect Analysis (FMEA)
Fault Tree Analysis (FTA)
"What-if" method
After checking for hazardous conditions and hazardous events, the risk factors are determined and the risks are estimated from
the degree or possible harm and the probability of the hazard occurring.
After estimating the risk, the risks are evaluated to determine whether the level of risk must be reduced. If the level of risk must
be reduced, safety measures, such as changing the design or providing safeguards, are taken.
ISO 12100 (-1/-2) has been formed into JIS standard JISB9700 (-1/-2).
The main purpose of this standard is to set out a framework and directions for general machine safety, so that designers can
design safe machines.
The introduction of ISO12100-1:2003 states that "The concept of safety of machinery considers the ability of a machine to
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perform its intended function(s) during its lifecycle where risk has been adequately reduced". The 3-step method, which is an
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the following page, but it does not yet seem to have been fully recognized in actual applications. ISO12100-2 sets out examples
of various measures, a sample of which are shown below.
Supplementary documentation or labels should notify of remaining risks, and necessary training, protective equipment, and
additional protective devices (6.1.1)
Emit an audiovisual warning (6.3)
Display manufacturer, model, and specifications of the machine (6.4)
Supplementary documentation to include storage conditions, mass, dimensions, and installation and disposal methods
(6.5.1)
The size of the machine risk is evaluated according to ISO 14121 and measures are taken to reduce the risk. Measures to
reduce risk, however, include design measures and mounting safety devices. First, the measures are taken in the design and
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the category that should be selected is determined by considering two factors: the degree of potential injury (from slight to
serious) according
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to always). The safety category for safety-related parts of control systems in sometimes assessed assigning one category for
the entire control circuit of one machine, and in other cases the category is assessed for each part.
For example, if a worker must periodically insert his hands between parts of a machine while it is operating to mount and
remove machine tool parts, F2 is selected. If the machine is rarely approached, F1 is selected.
(4) Categories
Describes risk reduction, which is necessary when designing and constructing safety-related parts of control systems and
devices. The categories represent a classification of the control system with respect to their ability to withstand faults and their
behavior in the event of a fault.
Basis for
Category Overview of requirements assuring
safety
B The safety-related parts of control systems shall, as a minimum, be designed, constructed, selected, Depends
assembled, and combined, in accordance with the relevant standards, using basic safety principles for the mainly on
specific application so that they can withstand: the selection
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☆ The following are examples of resisting operating environment stress. of
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・ Selecting materials that are resistant to the operating environment
・ External factors, such as mechanical vibration, external magnetic fields, power interruptions, and
disturbances
・ Compliance of components with relevant standards
Therefore, special safety standards do not apply to category B parts, and safety functions may decrease
when a failure occurs.
The requirements of category B and of this subclause shall apply. Safety-related parts of control systems to
category 1 shall be designed and constructed using well-tried components and well-tried safety principles.
☆ The following are examples of well-tried parts.
・ Parts that have previously been used for a broad variety of applications
・ Parts that are suitable for safety-related applications and that have had their reliability validated
☆ The following are examples of well-tried safety principles.
・ Protection using fuses when a short circuit occurs
1 ・ Decreasing the probability of failure occurrence by providing a margin in part dimensions and by lowering
the ratings
・ Defining the failure mode, such as by opening the circuit and turning OFF the power supply when a failure
occurs
・ Early detection of failures
・ Post-failure measures, such as grounding the device
Therefore, the probability of failure occurrence for category 1 is lower than that for category B. Safety
functionality may decrease, however, when a failure occurs.
The requirements of category B, the use of well-tried safety principles and the requirements in this subclause Mainly
shall apply. Safety-related parts of control systems to category 2 shall be designed so that their function(s) depends on
are checked at suitable intervals by the machine control system. The check of the safety function(s) shall be configuration
performed.
☆ The following are examples of designing for inspection at intervals appropriate for the machine control
system. Safety functions are inspected as follows:
・ Before starting the machine and before a hazardous condition occurs.
2 ・ Inspection periodically during operation if risk assessment and operation category require inspection.
Inspection may be started automatically or manually, but inspection of safety functions is one of the following.
・ If no failure is detected, operation is possible.
・ If a failure is detected, the output to start the appropriate control operation is output, and the output
produces a safe condition. If a safe condition is not produced (e.g., contact fusing in the final switching
device), a hazard alarm is output. After a failure is detected, the safety condition is maintained until there is
no longer a failure.
Therefore, in category 2, safety functions may be lost between inspections if a failure occurs.
The requirements of category B, the use of well-tried safety principles and the requirements in this subclause
shall apply. Safety-related parts of control systems to category 3 shall be designed so that a single fault in
any of these parts does not lead to the loss of the safety function. Common mode faults shall be taken into
account when the probability of such a fault occurring is significant. Whenever reasonably practicable the
3 single fault shall be detected at or before the next demand upon the safety function.
☆ Designing to prevent single faults from lowering safety functions, means, for example, the following:
・ Providing redundancy and diversity
・ Automatically checking safety functions
Therefore, safety functions may not operate if multiple failures overlap.
4 The requirements of category B, the use of well-tried safety principles and the requirements in this subclause
shall apply. Safety-related parts of control systems to category 4 shall be designed so that:
・ A single fault in any of these safety-related parts does not lead to a loss of the safety function.
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・ The single fault is detected at or before the next demand upon the safety functions, e.g. immediately, at
switch
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・ If this detection is not possible, then an accumulation of faults shall not lead to a loss of the safety
function.
(5) Validation
The safety category of safety-related parts is selected based on ISO 13849-1 to attempt to check and reduce the occurrence of
hazards associated with the entire machine based on ISO 14121.
Next, analysis and testing is performed to confirm that the safety-related parts conform to the requirements for the safety of the
entire machine.
Although the analysis is performed using a list of foreseeable faults based on ISO 13849-2 and design criteria based on ISO
13849-1, as an example, the following faults are excluded as examples of 'fault exception items'.
1. The NC contact of a safety switch with a direct opening/positive opening mechanism does not open.
2. The forcibly guided NC and NO contacts of a safety relay contacts are closed at the same time.
3. A secured cable reliably protected with a cable duct or other means causes a short circuit between wiring due to an
external shock.
4. A short circuit occurs in adjacent terminals whose connections are reliably covered with an insulating tube or other means.
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(6) Documentation
Items that are required to be documented are shown below, by category (extracted from ISO 13849-2 Table 2)
Category
Items Requiring Documentation
B 1 2 3 4
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● Main Changes
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The latest revision in ISO 13849-1: 2006 allows users to determine risk estimations homogeneously and uniquely, and makes
risk assessment easier for persons responsible for implementing it.
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As with the risk graph in EN954-1, a required performance level is evaluated in terms of severity of injury (S), frequency and/or
exposure to hazard
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ranging from "a" to "e" is determined depending on the scale of the risk.
<Meaning of Symbols>
S1: slight (normally reversible injury)
S2: serious (normally irreversible injury or death)
F1: seldom-to-less-often and/or exposure time is short
F2: frequent-to-continuous and/or exposure time is long
P1: possible under specific conditions
P2: scarcely possible
1. Category
2. MTTFd (Mean Time To Dangerous Failure)
3. DCavg (Average Diagnostic Coverage)
4. CCF (Common Cause Failure)
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The Categories
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the previous version of EN954-1.
MTTFd refers to an average life before the dangerous failure of a component. DC refers to the certainty of detecting failures in
the entire system including software. CCF refers to the protection of the entire system from failing due to a common cause. As
parameters for reliability, MTTFd and DCavg are determined by formulas, and CCF is determined with a checklist method.
Each of the parameters is classified into levels using standard values: three levels for MTTFd, three levels for DC and two levels
for CCF. Performance Levels are evaluated comprehensively in terms of these four parameters.
The following sections show how each of the parameters is calculated.
For example, with "Category 4, MTTFd=High, DCavg=High, CCF of 65 points or higher," then the PL is evaluated as "e".
However, the thresholds in the above graph for MTTFd determination are not easy to locate therefore the below table is
provided to give a more simplified view. Either the graph or the table may be used.
Category B 1 2 2 3 3 4
DCavg None None Low Medium Low Medium High
MTTFd of each channel
Low a --- a b b c ---
Medium b --- b c c d ---
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High --- c c d d d e
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*Notice that in both the graph and the table methods some combinations of parameters are not allowed. For example, combining Category 4
with medium reliability and low diagnostic coverage is not considered.
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2. Interlocking Devices
An interlocking device is a mechanical or electrical device that can prevent the machine from operating unless certain
conditions are met, such as closing a guard.
Provisions for interlocking are stipulated in ISO14120 for guards, ISO14119 for interlocking devices associated with
guards, and ISO13849-1 for the method that is used to process the signal from an interlocking device and to stop
machinery. This section describes interlocking parts linked to guards like safety limit switches and safety door
switches in accordance with ISO14119 along with a description of each.
Safety machinery and equipment consist of a control system and an operative system as shown in Fig. 1 Role of Interlocking
Devices. The power control element combines the roles of the control and operative systems, and machine actuators are
equipped with safeguards and interlocking devices.
Electricity is supplied to the power control elements only if a safety check signal is sent from the interlock device and an operate
command is sent from the control system.
The interlock device is used to send safety check results to the power control elements as shown in the figure below. A safety
signal can be sent from a PLC in some cases as long as the PLC does not have a negative impact on the interlock device.
In other words, the interlock device (safety-related part) and the PLC (non safety-related part) are completely independent of
each other.
Control systems are divided into safety-related and non-safety-related parts in international safety standards, and they must be
constructed so that non-safety-related parts do not have a negative impact on safety-related parts during normal operation or
when a malfunction occurs.
● Interlocking Types
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Controlon
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This type of interlocking device inputs a stop command to a control system, like an electromagnetic relay that interrupts or
removes the energy supplied to machine actuators.
Power Interlock
This type of interlocking device sends a stop command that directly interrupts or removes the energy supplied to machine
actuators.
Under the power interlock system, the control system does not intervene between the interlock device and the power supply, but
instead the interlock device itself uses a safety switch or some similar measure to control interlocking.
Non-locking Type
The guard can be opened or closed at any time and the interlocking device sends a stop command only if the guard is open.
Locking Type
(1) Unconditional Unlocking
An operator can unlock the guard at any time with this type of unlocking, but it does have a precondition in that it must take
longer to unlock the guard than it does to clear the hazard.
(2) Conditional Unlocking
The guard can be unlocked under certain conditions, such as when confirming that the hazardous condition has been cleared
(e.g. confirming that rotation has stopped).
Locking and unlocking types can be classified by the actuating mechanism that is used to apply and release the lock.
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OMRON uses a mechanical lock/solenoid release method.
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Power Applied, Spring Released Type
OMRON uses a solenoid lock/mechanical release method.
Mechanical lock and solenoid release Solenoid lock and mechanical release
Solenoid (Power) Lock
Note: In a specific application, either a "power applied, spring released type" or "power applied, power released type" may be used if they
provide an equivalent level of safety. In principle, however, the part (bolt) intended to provide the lock the guard must be the "spring applied,
power released type."
The following items must be considered in the design of interlocking devices that use a safety limit switch or safety door switch.
(6) Switches must be located, and if necessary protected, to avoid damage from external causes.
(7)
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Easy access for switch maintenance and inspection must be afforded. ✕
When selecting an interlocking device it is necessary to consider all phases of the interlocking device, including the conditions of
use and intended use of the machine, hazards present at the machine and their evaluation, stopping time and access time to
the machine, and frequency of access.
Frequency of Access
(Frequency of Opening the Guard)
(1) For applications requiring frequent access, conduct a risk evaluation and then select an interlocking device that provides
the least possible hindrance to the operation of the guard.
(2) For applications using interlocking devices with automatic monitoring, the interlocking device should be used with additional
measures, such as conditional guard unlocking, because the frequency of function checks decreases and the probability of
an undetected fault occurring increases as the opening frequency decreases.
The following control requirements must be satisfied for interlocking devices for movable guards (ISO 12100-1).
(1) Closing the movable guard enables operation of the machine that was covered by the guard. Closing the movable guard
causes the operation to start automatically. At actual startup, restarting can be performed by pressing the start button after
all other start conditions are met.
(2) The stop signal for the machine will be output if the guard is opened during operation of a machine that is covered by a
guard. In other words, the machine will not be permitted to operate as long as it has not been detected that the guard is
closed.
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When a fault or disturbance in electrical equipment leads to a hazardous condition and the possibility that the machine
as well as the item being processed may be damaged, appropriate steps must be taken to minimize the probability of a
hazard. This section uses the safety principles found in EN 60204-1 to describe and illustrate the main procedures to
follow to minimize risk in the event of a fault.
The fuse will blow and power to the circuit will cut off if a ground fault occurs on line A.
A ground fault will not occur on line B because it is grounded.
Two ground faults act as a bypass. As a result, the machine may start abruptly or its operation may not be interrupted.
B: Safety Circuit Transformer Grounded from the Midpoint on the Secondary Side
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A ground fault causes half the voltage to be applied to the relay coil. As a result, the machine in operation may not be
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interrupted. ✕
2. A procedure must be established to cut off power to stop control and power circuits instantly.
See (8) Emergency Stop for details.
The following are examples of redundant electric circuits that employ more than one relay or switch in combination so
the circuits will function even if one of the relays or switches fails to operate.
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(4) Use of
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Common malfunctions and the probability of failure in electric products can be reduced if each product uses a variety of control
circuits as well as various types of devices and components. The following are examples showing the use of diversity.
1. Safety door with safety components that use a combination of NC and NO contacts.
2. Circuits using control components that are different from each other in type.
3. Redundant combinations of electromechanical and electronic circuits.
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● Examples
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G9S-301 (24 VDC) - Two Limit Switch Input Channels
Fault detection 1: Detect closed door switches (K1, K2)Fault detection 2: Detect fused interface relay and contactor contacts (K3)
If the normally open contact (8) of the contactor is welded, the normally closed contact (7) will be neutral (not conducting), and
no voltage will be applied to the coil of safety relay K3. K3 will not operate, in which case the relay sequence will not operate
even if the reset switch (2) is turned ON and power will not be supplied. The auxiliary contacts of the contactor must be mirror
contacts.
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(2) There must be a potential difference between these channels.
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protection. ✕
● Safety Control Circuit with Two Input Channels and a Short-circuit Detecting Function
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The emergency stop function must work so that it falls under category 0 or category 1. The choice of category 0 or category
(4)
1 must
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Stop Category 0
Stop category 0 is an uncontrolled stop that is achieved by immediately removing power to the machine actuators (e.g., directly
cutting off the power supply).
Stop Category 1
Stop category 1 is a controlled stop that is achieved by sending a stop command from the control circuit to stop (e.g., brake) the
machine actuators and then removing power to the actuators (e.g., cutting off control circuit power) after the stop is achieved.
Stop Category 2
Stop category 2 stops machine actuators without cutting off the power.
(5) Where several emergency stop devices are provided in a circuit, it must not be possible to restore that circuit until all
triggered emergency stop devices have been reset.
(6) Emergency stop equipment must be used as neither an alternative to proper safeguarding measures nor as an alternative
for automatic safety devices, but they may be used as a back-up measure.
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The requirements for the emergency stop function as stipulated in IEC 60204-1 are as follows:
The emergency stop function must deactivate all other functions and operation in any mode.
The power supply for all machines that are capable of inducing a dangerous condition must be removed as quickly as
possible without causing any other dangers.
The reset function must not restart the stopped machine.
The relevant standards divide applications into numerous stop categories. The selection of the appropriate category must be
made depending on a risk assessment of the machine involved.
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4. Presence
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● Reflective
Features: Relative freedom in defining protected areas.
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● Pressure detection
Features: Excellent environmental resistance
When an operator enters a hazardous area, the machine in the area must come to a complete stop before that operator reaches
the hazardous part of the machine. Safe distance refers to the minimum calculated distance that the protective device must be
installed from the hazardous part of the machine.
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5. Two-hand Controller
One way to prevent operators from approaching hazardous areas too closely when conditions are hazardous is to
install two-hand controllers at specified locations.
The guidelines for designing Two-hand Controllers are given in ISO13851. The major safety requirements for Controller
design are listed there under Functional Aspects and Principles of Design for Two-hand Controllers.
Note:Conduct actual designing in compliance with the detailed stipulations of ISO13851.
The characteristics that must be provided are categorized by type into Type I, Type II, and Type III categories. The major
characteristics listed here are Type III characteristics used in Category 3 and 4, as determined by risk assessment.
(1) Two hands must be used together to start up the machine.
(2) Two input signals are required to produce an output signal.
(3) The output signal must turn OFF if either or both input signals turn OFF.
(4) Both input signals must be turned OFF before the output signal is restarted.
(5) Both input signals must turn ON within 0.5 s to enable synchronous startup output.
(6) Preventing inadvertent startup and disable prevention: Refer to Article 2.
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Note: A shield must be installed between the two startup switches. This does not apply to applications where disable prevention is possible.
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Install a cover or enclosure.
4. Disable Prevention with One Hand and Another Part of the Body
Install the startup switches at least 1,100 mm off the floor or from the operating level to prevent operators from employing
disable prevention with one hand and another part of the body (e.g. knees, hips, etc.).
Note:Safe Distance
The safe distance from the startup switches to the hazardous area must be calculated using factors such as hand and arm speed, response
time of the startup switches, and maximum time required to eliminate a hazard according to ISO13855.
5. Typical Example
Fig. 1 shows a typical example of a Two-hand Controller according to Articles 2.1 to 2.3.
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6. Enabling Switches
An enabling switch is a safety component used so that workers can avoid unexpected machine movement when
performing non-scheduled maintenance work or other non-scheduled operations in hazardous areas, such as those
inside safety fences.
When a worker is using a hand-held console with operation switches to teach a robot, retool, or perform maintenance,
unexpected movement of a hazard can result in a hazardous state. When this occurs, it's impossible to predict whether
the operator will instinctively release the console or will grip it with force. A normal switch thus does not turn OFF
when excessive force is applied, which may result in a worker accident.
With an Enabling Switch, machines or robots can be controlled only when the switch is gripped lightly to the middle
position. If the switch is gripped with force past the middle position or if the switch is released, the machine or robot
will be shut OFF, disabling operation.
Enabling Switches are normally used built into teaching pendants, grip switches, and other hand-held controls. They
can be combined with safety circuits built with Safety Relay Units and other devices to ensure safety.
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1. Periodic confirmation tests are conducted, showing that there are no latent hazards.
For example, a failure is detected in self-diagnosis and a safe state is achieved.
2. Reliability with respect to deterioration and lifetime of assembly components.
For example, the probability of a hazardous failure is determined for each part.
3. System reliability.
It is confirmed that protection against one type of hazard will not invite a different type of hazard.
IEC 61508, which was issued in 1998, is representative of common standards for functional safety. IEC 61508 is further divided
into seven detailed standards for individual fields of application. Standards for industrial machinery are stipulated in IEC 62061.
For detailed information, refer to these standards.
In the above standards, the SIL (Safety Integrity Level) is defined as parameters that specify the requirements of safety
functions. In the area of machinery, it has been decided to coordinate the SIL with the performance level (PL) defined by ISO
13849-1,2006.
(Extracted from the NECA Safety Guide Handbook.)
The required SIL (Safety Integrity Level) is greatly determined by whether the operation demand is low or high/continuous.
SIL Required of Safety-related Controls in Low Demand SIL Required of Safety-related Controls in High or
Mode (for Example, Safety-related Controls That Operate Continuous Demand Mode (for Example, Safety-related
Only for a Short Time When There Is Demand, Such as ABS Controls That Operate Continuously or Frequently over a
on Cars) Long Period of Time, Such as a Pacemaker)
Example: If risk assessment determined that SIL2 is suitable, Example: If risk assessment determined that SIL2 is suitable,
the TFM that needs to be achieved by the related safety the
controls would be 10-2 < TFM ≥ 10-3. TFM that needs to be achieved by the related safety
Note:TFM (Target Failure Measure) controls would be 10-6 < TFM ≥ 10-7.
SIL (Safety Note:TFM (Target Failure Measure)
Low operation demand mode (average
Integrity SIL (Safety
failure rate per operation demand) High or continuous operation demand mode
Level) Integrity
(hazardous failure rate per unit time (1/h))
4 ≥ 10-5 to < 10-4 Level)
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