Types of Interlocking Device

Interlocking devices or interlocks refer to the mechanical, electrical or other type of device, the purpose of which is to prevent the operation of hazardous machine functions under specified conditions. The standard that provides detailed definitions regarding interlocking devices and guards is EN ISO 14119 and provide rules and regulations to abide by to reduce the defeat of interlocking system. Additionally, the standards EN ISO 14119 also defines the types of interlocking devices in detail and included those that were not previously mentioned in the EN 1088. For instance, non-contact devices, coded and un-coded devices, including magnetic, inductive, ultrasonic, capacitive, RFID and optic are those that were no previously defined in the scope of EN 1088. The examples of these with related use is provided in the Annex C and Annex D of EN ISO 14119.

If we take into an account the coded interlocking devices the standard EN ISO 14119 defined it as the actuator that is designed specifically to actuate a specific position switch. Different levels of coding are also specified such as low level coding (variations of 1 to 9 are present in coding), medium level coding (10 to 1000 variations) and high level coding (more than 1000 variations are available. The table below provides an overview of the types of interlocking devices.

Guard locking

The standard EN ISO 14119 also specify and expands the type of guard locking from power to lock or power to release and include bi-stable locks in which power is applied to lock and to release a solenoid guard switch. It further discuss the permissibility of electromagnetic locks (the use of electromagnetic force without the tongue) under such circumstances as to ensure the safety of the machine taking into account such considerations as the distance to the potential hazard, monitoring of the holding force, in the event of power loss the stopping of time and indicating any event of forced entry. The standard also differentiates between locking for personnel protection (against injury) and locking for process protection (against interruption).

Annex A of the standard EN ISO 14119 offers guidance o static action forces based on the direction of opening force, posture and type of operator grip that is single or bi manual. It is the responsibility of manufacturer to specify the interlock strength that resist static action force and the designer to identify the required holding force related to an interlock guard. The table below shows the examples of static action forces as implied by the EN ISO 14119.

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Top 3 Indispensable Requirements for Machine Control System

There are variety of requirements related to machine control system according to the machine directives provided by European Commission and International Standardization Organization. Generally, there are three main types of requirements if you are a manufacturer of the machine and related equipment. These include fast and flexible programming, seamless connectivity, and simulation and augmented reality.

1 – Fast and flexible programming

In a competitive environment where many machine manufacturers present their machinery, those with flexible customized equipment and capable to function rapidly as well as reliably are more encouraged than that of the machinery with opposite abilities. For instance, the introduction of pre-developed and tested equipment eliminates heavy-lifting control that reduce programming time by almost 70 percent. These features enables the manufacturer to spend more time on other features that really make difference in machine functioning.

2 - Seamless connectivity

Data is important in modern productive environment. The data analysis techniques are becoming more smart and providing improvement in quality, quantity, reliability, productivity, efficiency and other areas of utmost importance. The modern technology also enable the manufacturers to record the valuable information and share it through fieldbus connections to improve the performance of the product. This can be achieved by converting the data into valued data that provides maximum benefits to the customers. The ways in which this feet can be achieved is by remote monitoring and troubleshooting capabilities and the introduction of automated intelligent predictive maintenance solutions.

3 - Simulation and augmented reality

The simulation and augmented reality make the process of evaluation of ergonomics and human interface faster and effective. Both manufacturers and customers want solutions that are fast as well as reliable saving both time and money. Motion and control equipment makers are embracing the trend that provide an edge to their hardware consisting of appropriate digital models and simulation tools.

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Significance of Appropriate Protection for Electrical Equipment

There is a lot of significance for appropriate protection for electrical equipment. It helps in protecting and preserving the valuable assets for a long time. If in any way, a harm befalls on the equipment, the optimal functioning level gets disturbed that also reduce the efficiency and reliability of a business and downgrade the performance in the competitive market. The backbone of industrial space is its machinery that has many critical and sensitive components such as electrical motors, drives etc. without any electrical component, the machinery is just a box that serves no real purpose. So electrical equipment must be housed in a protective enclosure to achieve the optimum level of functioning. High quality enclosure and climate control equipment serves as the best environment to safeguard the equipment.

High Temperatures

High temperatures impact he equipment negatively and reduce the total lifespan which resulted in unexpected breakdowns, high cost and reduced performance and productivity. Output cannot be generated 100 per cent when the temperature exceeds the limit. To prevent such circumstances, appropriate cooling equipment should be installed such as fans and filters, cooling units, or water-air heat exchangers.

Low Temperatures

Though the statement comes as a surprise yet protection from low temperature is also necessary for electrical equipment. When the temperature drops, functioning of any idle equipment drastically reduced. Low temperature also increase viscosity of oil and creates problems in motors or compressors, causing failures. For prevention, the appropriately sized heaters should be placed inside the enclosure. Heater will maintain an acceptable temperature when it is connected to thermostat to prevent the damage.

Condensation

Condensate can cause significant damage to the sensitive equipment when it produces inside the enclosure in humid environments. If left unchecked, it causes catastrophic damage to the equipment. Prevention can be done by using industrial enclosure with an IP54 seal to prevent damage from humid air. An additional cooling unit can also act as de-humidifier and removes excess condensate from the pocket of air within the sealed enclosure.

Corrosive Substances, Dust and Dirt

Carbon dust in the steel and manufacturing industry, salt water vapor in the air in a coastal application, yeast or vinegar extract in the food and beverage industry are some of the examples of equipment that destroy the electrical equipment in industrial space. These contaminants as well as dusty environment can easily corrode connections and produce hazards of heat and fire. In these environments, cooling product should be used that prevent any dirt to enter into enclosure. Other options include air to air, air to water, heat exchangers and cooling agents which reduce the contaminants in the immediate environment of the electrical equipment.

The Factors that can affect the electrical equipment should be kept in mind or an advice from experts must be ensured to deal with the potential damages to machinery and related electrical equipment.

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Selection of Guards as per EN ISO 14120

EN ISO 14120 is the standard that specify the guarding requirements for the manufacturer as well as the users who could in future add to the existing guards of the machine. The European standard EN ISO 14120 is titled Safety of machinery - Guards - General requirements for the design and construction of fixed and movable guards. It is highly prescriptive and descriptive as to leave the little room for interpretation for the machine builders on individual level. It came as an addition to the previous standard EN 953 and carries following provisions

  • Section 8 is then modified into section 7 titles verification of safety requirements of guards and specifically mention verification procedures outlined in Annex C. it provides a complete guide related to the selection of guards after the assessment of location of hazards in addition to providing flow chart for the ease of process. In case of unfulfilled legal gaps in manufacturing a legal action is necessitated to hold manufacturers accountable for any hazardous accident.
  • Annex B provides of the standard EN ISO 14120 provide the flown chart for the selection of guards generated by moving parts against the hazards. For instance, flow chart asks questions about the access requirement for setting, process correction and maintenance or the frequency of access per month or twelve time in the whole year etc.
  • The standard put certain conditions on the use of fixed guards such as determining if their replacement or removal is easy or not keeping n view the machinery that is built before the standard is published
  • The selection criteria of the type of guards as implied by Section 6 of the standard depends on
  1. The use or intended use of the machine
  2. The frequency and nature of access permitted
  3. The hazards associated with the machine
  4. The probability of any severity in relation to an injury by assessment of risk.
  • Another provision of the standard include misuse and defeat of guards. These provisions make a manufacturer aware of the situations in which guards could interfere with the normal functioning of machine and how an operator disable guard. This looking beyond the obvious and intended use of machine necessitated the thorough documentation of risk assessment providing a new area in which manufacturers will think more deeply about how their installations are approached and specifying requirements for guards when these are attached to a structure.
  • The consideration according to EN ISO 14120 is given to number and types of fixing, fixation to floor, assembly of movable guards and compliance with other relevant regulations
  • Section 8.5 that deals with removal of guards provide additional description on the requirements attached to the appropriate usage of tools

Though material changes are not significant in the standard yet detail is provided regarding many aspects of the guarding in machines. The description provided leaves a little room for individual and subjective interpretation and sometimes call for expert advice on assessing the regulatory requirements as described in the standard EN ISO 14120.

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Positioning of Electrical Enclosures

An electrical enclosure is a cabinet or box that protects electrical or electronic equipment and prevents electrical shock. Electrical enclosure positioning is a matter of utmost concern as the other matters such as the material which is best suited to make an electrical enclosure, which method is optimum related to cable entry method for particular installation, how the identification of IP rating is done and any other technical issue. There are different points that must be kept in mind when choosing the position of installation for electrical enclosure.

Ease of installation

The electrical enclosure must be installed in a places where it is accessed easily. No one likes to spend extra time searching for the enclosure and then fixing the problems. Accessibility must be on priority list when deciding position of enclosure. Easy access will make the job easier of mounting easier, faster and free of mistakes. Though ease of access is suggested yet the care must be taken in hiding it from general public view to avoid any threatening situation such as vandalism, disruption or theft. The feature of height can be utilized in this regard e.g. the enclosure should not be accessible while standing but through using step ladder or small stool.

Getting outdoors

The enclosure are suggested to be installed outdoor usually on the exterior wall of the building. However, the care should be taken as to avoid any environmental stresses to comply with IP rating practices. The enclosure can also be set on the leeward side of the building as to shield from the extreme weather. The final aim is to provide protection from external threats whether natural or other.

Avoiding accidents

The accidents are bound to happen in certain high risk areas. Though many of the robust enclosure get protected by sudden forceful hits but most are not designed this way. A place where these type of accidents can be avoided should be first priority. In high traffic areas the threats are as many such as miss kicked footballs, interferences of passers-by, dropped load, poorly controlled shopping trolleys or pallet trucks. Further locations such as visitor’s attractions, museums, restaurants, schools, theaters etc. demand that enclosure tampering is avoided to make them of of reach.

There are certain robust enclosures that withstand high pressures or conditions and these should be specified as such. In case of other enclosures that do not possess these capabilities, expert advice should be taken to avoid any hazardous situation.

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Machinery Directive 2006/42/EC and Pressure Equipment Directive 97/23/EC

Pressure Equipment Directive 97/23/EC related to Machinery Directive 2006/42/EC underlines the regulations that includes pressure equipment and assemblies of pressure equipment with an allowable maximum pressure of more than 0.5 bar and where the equipment defined as piping, vessels, pressure accessories and safety accessories. There are number of exclusion that has to be kept in mind when deciding if the equipment under consideration falls into the category of Pressure Equipment Directive PED 97/23/EC, the information of which can be found in paragraph 10 in Annex A that corresponds to Clause 3.10 of the PED.

After deciding the scope of the relevant directive it is important to realize the equipment type and fluids that are present in the equipment. Equipment can be of

  • Vessel type resembling a housing that contain fluid under pressure
  • Or piping that covers those components which are intended to use for transport of fluids and are integrated through connection with each other into a pressure system
  • Or it could be steam generator example of which is boiler.

The fluid can be in the form of liquid or gas constituting either Group 1 or Group 2.

  • In case of any doubt the fluid should be treated as a gas with the conditions such as vapor pressure more than 0.5 bar at the maximum allowable temperature for equipment.
  • Group 1 included all categories of flammable, explosive, oxidizing, or toxic fluids while Group 2 constitute the remaining types of fluids.
  • The information about the vapor pressure of the fluid should be readily available from the supplier of the fluid to avoid any unfavorable situation.

The manufacturer and relevant personnel should have an idea about the product classification that has been given in the table of product classification shown below:

with the determination of the type of equipment and deciding whether the fluid belongs to Group 1 or 2, the table corresponds to the nine charts that are present in Annex B of the directive publication that make it easy to identify method of compliance with the PED

The chart that is shown below also shows the procedures that must be follow to achieve the compliance with Pressure Equipment Directive PED. The volume has plotted along the horizontal axis and pressure on the vertical axis. To use the chart, the point corresponding to the volume of the equipment under consideration and the maximum pressure to which it will be subject is located on the chart. This point will fall into one of the five regions as defined by the curves on the chart. The regions are named as SEP, I, II, III and IV and indicating the category of the equipment which in turn specify the procedure related to PED.  In some cases for pipework where volume is hard to determine, the charts use instead a nominal size (DN). This is only loosely related to the pipe's physical diameter, and the DN figure should, therefore, be obtained from the manufacturer or supplier of the pipe.

The step by step guide provide an ease to comply with the Pressure Equipment Directive in an efficient and vivid manner.

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Machinery Directive 2006/42/EC and Low Voltage Directive 2006/95/EC

Machinery directive 2006/42/EC and Low Voltage Directive 2006/95/EC specifies the safety requirements related to electrical equipment within certain voltage limits and are essentials for the manufacturers who intend to sell their products in national and international markets. The voltage limits provide high level of protection for the users of machinery and related equipment and covers the range between 50 and 1000 V for alternating current and between 75 and 1500 V for direct current and the voltage refers to the input and output voltage not the voltage that appears inside the equipment. The low voltage directive has 16 articles and 5 annexes. The directive covers health and safety requirements covering all the risks associated with the high voltages and rendering the equipment safe for its intended use.

The guide to application of the machinery directive 2006/42/EC that was published by European Commission states that declaration of conformity in case of machinery directive is not referred to low voltage directive. However, the same guide also make it essential to comply with low voltage directive “the safety objectives set out in Directive 73/23/EEC shall apply to machinery." And Directive 73/23/EEC, which has recently been re-designated 2006/95/EC, is the LVD (Low Voltage Directive). The declaration is not necessitated but conformity with the low voltage directive should be ensured. The guide also provides details as to how machine builders ensure the conformity with low voltage directive by providing general specification of electrical equipment design in EN 60204-1 and specifications related to high voltage electrical equipment in standard EN 60204-11. The part of most interest is EN 60204-1 as very few machines incorporate high voltage electrical equipment. However, it is not the only standard that deals with the related specification of electrical equipment. The machinery and electrical equipment manufacturer must exercise caution when they determine which standards apply to their equipment. For instance many electrical engineers rely on 17th edition of the IET Wiring Regulations (BS 7671) for guidance yet it is not applicable to guidance related to machinery.

EN 60204-1 therefore gives indications to the manufacturers in relation to design and construction in general terms. It deals with various sections of machinery and related electrical equipment such as supply conductor terminations and disconnection/isolation devices; protection against electric shock; protection of equipment; equipotential bonding; control circuit and control functions; operator interfaces and machine-mounted control devices; control gear location, mounting and enclosures; conductors and cables; wiring practices; electric motors and associated equipment; accessories and lighting; and marking, warning signs and reference designations. It also covers technical documentation and verification/testing. The overview showed that compliance to the international regulations is not an easy task and a lot of time and effort could be saved by using expert advice.

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Machinery Directive 2006/42/EC and EMC Directive 2004/108/EC

The machinery directive 2006/42/EC and EMC Directive 2004/108/EC deals with the machinery and related components that could have potential electromagnetic issues, either conducted or radiated, or susceptible to electromagnetic radiation, generation or any related hazard. The control system of machinery or any electric or electronic system associated with the equipment thereof can produce electromagnetic disturbance that could create a dangerous situation and malfunction in the machinery. The EMC Directive, 2004/108/EC was put in place to deal with such situations. The section 2 of the guide further states to cover essential requirements of manufacturing and design of equipment in a way that electromagnetic disturbances produced are not excessive and is immune to external electromagnetic disturbances. The guide also directs to include sound engineering practices in case of fixed installations machinery and equipment though these are not covered specifically under this directive and do not require CE marking. The design and manufacturing of fixed installation must meet the specific performance and safety criteria for efficient working. If machine is not a fixed installation, the CE marking requirements must be fulfilled in respect to electromagnetic compatibility of machine. The manufacturer must give due importance to the assessment of fixed vs not-fixed installation as it is confusing a number of times. The general opinion is that manufacturers should check the EMC of the machine as it saves from potential hazards.

The importance of this directive can be assessed by the fact that proper precautions are necessary to ensure that the machinery fulfils the requirements of electromagnetic capability. It is essential to use such components in the manufacturing of machine that fulfil the conditions of electromagnetic capability. If the certain component of the machinery is compliant to the regulations, it does not mean that addition of two or more of such components also remained compliant to the directive. The complete evaluation of the electromagnetic compatibility performance of the machine is only possible through standardized testing of some accredited body that would provide a proof of compliance with EMC regulations and is recommended by Section 6 of the Health and Safety at Work Act (HSW). The process of meeting EMC requirement is a bit daunting and only a specialist consultant could provide the essential resources for meeting the criteria of Machine directives related to EMC. The process would further build a trustworthiness of specific businesses and provide a room for growth and competition in international and national markets.

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Interlocking Devices Associated with Guards

The standard EN ISO 14119 is a standard the deals with the safety of machinery with special reference to interlocking devices associated with guards. It is a new version of the standard EN 1088. Interlocking devices or interlocks refer to the mechanical, electrical or other type of device. It prevents operation hazardous machine function as specified by certain conditions (generally as long as a guard is not closed). Guard is associated with an interlocking device and together with the control system of the machine under consideration is presumed to perform these functions such as

  • The hazardous machine functions "covered" by the guard that cannot operate until the guard is closed;
  • If the guard is opened while hazardous machine functions are operating, a stop command is given;
  • When the guard is closed, the hazardous machine functions "covered" by the guard can work effectively (the guard closure does not by itself start the functions of hazardous machine)

It includes in its scope technologies such as RFID or electromagnetic guard locking, made classification of interlocking devices and provide clear regulations and specifications of installing guards. All these points are used to prevent against the guard manipulation, which is known as the term defeating of guards. This international standard is developed by ISO, the International Standards Organization and is widely accepted in the international markets even replacing the standard BS EN 1088 in the UK. The standard do cover the parts of guards that actuate interlocking devices however it does not necessarily include the requirements specific to trapped key systems.

EN ISO 14119:2013, also known as EN ISO 14119 in Europe and BS EN ISO 14119 in the UK, provides a wider scope to manufacturers and users of machinery and include in its scope wider range of technologies related to interlocking guards. The responsibility is placed on the designer of the machine as to make such design that reduce the foreseeable, deliberate defeating of guards by such productive alterations that the guards do not hamper with the functioning and productivity of machine. It also revolutionized the way in which the guard interlocking devices are connected across variety of machines. Machine builders are always at advantage by adopting the safety gate system and design in such manner that comply with the standard EN ISO 14119 further minimizing the challenges such as fault masking and provided new competitive capabilities in the market through compliance with the international standard.

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Heat Management in Electrical Enclosures

Electrical enclosures are prone to many hazards that trigger significant damage to electronic and electrical components present inside. One of them is heat. The air that is enclosed in a space can heat up rapidly. When the phenomenon occurs in an electrical enclosure it damages the equipment present inside and shorten its lifespan. The condensation that is formed as a result cause short circuits, rust and other problems. Additionally, the sensitive components that is present in an electrical enclosure could face potential damage due to fluctuations in internal temperature.

There are different cautions that are practiced by the engineers during the phase of design and installation to alleviate the high-end damage to the electrical enclosures and to the equipment.

  1. Site for the enclosures is selected to keep it away from direct sunlight, heat sources, etc.
  2. The locations where there are temperature fluctuations must be avoided, such as in kitchens or near furnaces if possible
  3. The damp or humid areas can damage the equipment so stay clear of damp areas, waterside locations and places where steam or water splashes are possible
  4. Do not make enclosures with electrical equipment taking all the spaces; instead, make sure there is enough room to allow a free flow of air
  5. Apart from ensuring the space inside, there should be enough space around the enclosure for air circulation
  6. If an enclosure is installed on a wall, it is necessary to provide an airspace or heat sink between the wall and enclosure
  7. Some electrical equipment will generate heat when in use. Identify such materials and provide extra space as well as decide appropriate position such as near the top of the enclosure and, if appropriate, provide ventilation
  8. Before placing lid seals, keep it in mind that they will restrict ventilation and heat dissipation
  9. Forced draught or even water-jacket cooling is essential in some cases
  10. Always seek an advice from experts on thermal management issues so they will be able to do detailed calculations and provide optimum recommendations

The material used in the construction of an enclosure also provides an idea about heat generation. For instance, metal enclosure will conduct more heat than the plastic ones whereas bare metal conduct more heat than the painted metal enclosures. But plastic material is better at resisting ambient temperature rise whereas metal ones are better at dispersing internally generated heat. Additionally, rate of heat generation and dissipation depends on surface area as well as environmental factors. Extra seals may prevent some external threats but in turn may produce more heat than usual. Similarly, more heat may escape from the top rather than through the bottom. All these factors call for an expert advice who can look up to standardized tables, graphs or software to provide reliable answers.

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