Machine guarding overview November 19 2024 | Blog Post, Venus Automation When considering hazardous areas on machines such as crushing/impact, entanglement, laceration, stabbing, and abrasion hazards, it is important to understand two main ways to guard operators from interacting with them. The first option, which we have discussed extensively, are electro-mechanical solutions. These include electrical interlocks, mechanical interlocks, safety switches (both contact, and non-contact), and photoelectric sensors. The second, often more simple solutions lie within permanent and fixed guarding. Permanent machine guarding, as the name would suggest, is an inherent guard built into the design of a hazardous machine. For example, an AC motor has a spinning shaft that is hazardous once it reaches its operating speed. They can pinch, cut (if there are blades/gears), and generally harm operators. To mitigate this, a metal sheet welded onto a machine to form a barrier, or housings between a motor and a gearbox would make the shaft of an AC motor inaccessible when assembled. Permanent guards are integrated into the design and cannot be removed. Generally speaking, the use of  permanent guards in hazardous areas is not feasible if the machinery contains serviceable parts, and thus requires maintenance. This is where fixed guarding becomes valuable. Fixed guards are considered as semi-permanent physical barriers between operators and hazards. They include fencing, tunnel guards, or roller cover guards. If these fixed guards are not interacted with frequently, this form of fixed guarding is sufficient. However, in the case of access doors, panels, gates, and moving guards that allow conditional access to a hazard (it should not open when the machine is running), interlocked guards are required. This blog post will briefly explore some machine guarding options – two fixed, and two interlocked. Fixed Guards – Axelent Fencing Fencing is a crucial form of fixed guarding in the industrial workplace. Fixed guarding through fences and barriers prevent access to hazardous machinery, and prohibit operator-machine interactions during dangerous operations. By creating a physical barrier, fencing ensures that workers maintain are safely distanced from hazards brought about by moving heavy machinery. There are different types of fences, including perimeter fences and distance guards, which are strategically positioned to limit one’s reach into a hazard. Furthermore, horizontal and vertical spacing of mesh is also a factor that is considered by fence guarding designers. Reaching in through a grille, and through square/circular appertures (the gaps in fences) all have acceptable and expected measurements such as the distance from the danger point (safety distance), along with the separation between each line of fencing. Beyond this, fixed guard fencing with access points may also be designed to limit movement from operators so that entry of a limb into a hazardous area is limited. Examples of this would be adding an arm support that extends to joints depending on the angle/range of the hazard. For example, these guards can support up to the knuckle joint, the wrist joint, or the shoulder joint. Fences are often installed based on reach distances—guidelines that determine the minimum safe distance from the hazard based on ergonomic factors and the likelihood of someone attempting to lean over or reach through the fence. Axelent’s X-Guard safety fencing system is a versatile and modular solution designed to meet the latest safety standards, including the Machinery Directive 2006/42/EC. This system offers various configurations for effective machine guarding, including mesh panels, posts, and door options (hinged or sliding). It ensures comprehensive perimeter protection, preventing   access to hazardous areas while maintaining visibility and accessibility for maintenance. Additional accessories, like cable trays, enhance functionality and installation efficiency, making X-Guard an adaptable choice for industrial environments. Fixed Guards – Concertina Roller Guards Another option for fixed guarding that presents itself in industry is roller guards. Roller guards are ideal for tight, limited spaces, and are also capable of expanding (and locking in place) and retracting. This enhances the flexibility of these guards, enabling hazardous areas and environmentally sensitive moving parts to be effectively fenced-off from operators. However, since they can retract, Concertina guards do not limit the ability for operators to remove the cover guards to carry out maintenance on any serviceable parts. Commonly used on fitting, turning, and CNC machine tools, Concertina guards are a durable ‘curtain’ type of guard that shield contaminants like dust, debris, and corrosive/caustic liquids from entering sensitive machines and sensors. When rolled up, Concertina guards are compact and low-profile; but can always be expanded into their full size. Typically comprised of a metal (most likely aluminium or steel) housing and coated fabric, Concertina guarding is chemically inert, and resistant to oils, acidic, and basic liquids. The end tabs of each roller are often some form of metal cladding, enabling the guards to be bolted into a desired spot for more permanent guarding, while also providing protection from the edges of the roller fabric from fraying. Enhancing their flexibility even further, Concertina roller guards are made to customer specifications, allowing them to be made to suit whatever measurements and spaces the customer requires. Overall, this form of fixed guarding ensures cleanliness, precision, and safety of machine operation. Concertina roller guards contribute greatly to workplace safety by barring operators from hazardous parts. Machine Guarding: two-hand controls Introduction When fixed guarding is less viable/sufficient to protect workers from hazards, different approaches need to be taken to guard operators in other ways. Not unlike fixed guarding methods, some electro-mechanical safety solutions also aim to inhibit the movement of machine operators. To achieve this, two-hand control systems have been developed. Similar to AND gates in Boolean logic, a two-hand control needs an operator to depress both buttons to enable continuity of power flow. Similar to fencing or roller guards, a two-hand control restricts the movement of an operator to only within a tight radius around the machine. Typical Applications Typical applications for two-hand controls as a form of machine guarding include: Hydraulic presses, punches, and stamping procedures Cutting equipment such as automated shears/guillotines Packaging/clamping/sealing machinery Press brakes and metal bending machinery Injection moulding machines. Two-hand controls are useful when an operator’s involvement is essential to start/stop a machine; enhancing safety by enforcing deliberate engagement from a safe distance. Limitations Limited Hazard Protection: While two-hand controls do ensure that an operator’s hands are kept safe, it is important to understand that

The Master overview of Safety switches and sensors Novemeber 11 2024 | Blog Post, Venus Automation Safety switches and sensors are essential components in modern industrial automation, providing critical protection for both personnel and equipment. Designed to detect potential hazards and initiate control responses, these devices prevent accidents by ensuring machinery operates only under safe conditions. Safety switches and sensors are widely used in various sectors, including manufacturing, automotive, food processing, and healthcare, where stringent safety standards are crucial. Far more than simple components, safety switches, non-contact sensors, electronic key systems, mechanical interlocks, solenoid locking switches, multifunctional gates, and safety bolts are the guardians that help protect both equipment and personnel.     These devices work quietly yet diligently, ensuring that when issues arise, they trigger immediate responses to minimize risks of injury and equipment damage. They consistently monitor activity, ensuring each machine operates within safe limits, thereby supporting the smooth, efficient functioning of industrial processes and reducing dependence on human oversight.   In this blog, we will explore various safety devices, including enabling switches, position/limit switches, foot pedal switches, and delve into non-contact sensors like safety inductive proximity sensors, magnetic coded sensors, RFID coded sensors and stainless steel electronics. The importance of electronic key systems and the versatility it provides. Mechanical interlocks that have plastic, metal and stainless steel interlocks. Reviewing the solenoid locking switches including electro magnetic and tongue varieties. The unique functionality of multifunctional gates, and the ergonomic applications of safety bolts. Join us to discover how these essential components are vital to creating a safer, more productive industrial environment. Safety switches : an overview Safety switches, also known as disconnect switches or residual current devices (RCDs), are essential components in electrical systems designed to protect people and property from electrical hazards such as electric shock and electrical fires. These devices are crucial for maintaining the safety and integrity of electrical installations across various applications, from residential settings to complex industrial environments.   Safety switches serve multiple purposes: Fault Protection: They provide critical fault protection for motors and heavy machinery by monitoring electrical currents. If a fault is detected, such as a short circuit or an overload, the safety switch will automatically disconnect the power supply, preventing potential damage to equipment and reducing the risk of fire. Disconnecting Means: Acting as a reliable disconnecting means for service entrances, safety switches enable safe maintenance and servicing of electrical systems. They allow technicians to isolate electrical circuits before performing repairs or inspections, ensuring a safe working environment. Current Leakage Detection: Residual current devices (RCDs) specifically monitor the balance of electrical current between live and neutral wires. If an imbalance occurs, indicating potential leakage to the ground (which could lead to electric shock), the RCD will trip and disconnect the circuit within milliseconds. Enhanced Safety Features: Many modern safety switches come equipped with additional safety features such as manual reset functions, test buttons, and indicator lights that signal operational status. These features enhance user safety and facilitate easier troubleshooting and maintenance. Regulatory Compliance: Safety switches are often required by electrical codes and regulations to ensure safe electrical installations. Compliance with these standards not only protects individuals but also helps prevent costly damages and liabilities for businesses.   By integrating safety switches into electrical systems, industries can significantly reduce the risk of accidents and create a safer working environment for employees. Their versatility and reliability make them indispensable in protecting against electrical hazards and ensuring the smooth operation of machinery. Types of Safety Switches Enabling Switch Position/Limit Switches Foot Pedal Switches Enabling Switches Enabling switches are critical safety devices designed to allow operators to control machines or processes in hazardous environments. These switches require continuous pressure to remain activated, offering a fail-safe solution if the operator releases the switch due to danger or discomfort. Often used in manual operation tasks like robot teaching or maintenance, enabling switches enhance safety by providing a controlled stop mechanism. They are typically three-position switches, offering multiple levels of control. DOLD – RE 6909 | Three Stage Enabling Switch Enabling switches EUCHNER ZSM Enabling Switch Euchner multi-function ZSM switch EUCHNER ZSB – Enabling Switch Euchner multi-button ZSB switch EUCHNER ZSA/ZSR – Enabling Switch Euchner single-button ZSA & ZSR switch ELFIN – 060P2MA | Two Hand Station Two-handed control station with button cutouts ELFIN – 060C2MA | Two Hand Control Station Two-handed control station SCHLEGEL – SZU_C002 | Enabling Switch Enabling Switch – SZU_C002: The SZU_C002 Enabling Switch from Schlegel ensures optimal safety in industrial…[+] Pizzato FD 2016-M2 Position switch with roller and stainless steel piston plunger The type FD 2016 position switch has metal housing in conjunction with the high degree of protection IP67 permits use under extreme ambient conditions. Pizzato FD 2031-M2 Position Switch with Roller Lever The type FD 2031 position switch has metal housing in conjunction with the high degree of protection IP67 permits use under extreme ambient conditions.. Pizzato FD 2056-M2 Position switch with adjustable length roller lever arm The type FD 2056 position switch has metal housing in conjunction with the high degree of protection IP67 permits use under extreme ambient conditions. Pizzato’s FD Series Safety Limit/Position switches play a crucial role in automation, serving as reliable safety devices. These position switches, designed by Pizzato, are widely installed in industrial machinery worldwide. Their versatility allows them to adapt to various configurations, making them essential components for ensuring safety in automated systems.  With a focus on safety, the FD series of position switches is engineered to withstand challenging environments. Featuring a robust metal powder-coated body, these switches achieve a high level of protection with an IP67 rating when combined with compatible cable glands. Pizzato’s FD Series Safety Limit/Position switches are indispensable safety devices that enhance automation systems, offering versatility, durability, and adherence to safety standards. What is a Foot Switch? A foot switch is a rugged electrical switch that can be activated by the simple application of foot pressure. It alters electrical contacts within a circuit when pressed. These switches are

CESE-level Risk Assessments November 12 2024 | Blog Post, Venus Automation Here at Venus Automation, our goals lie within maximising safety, compliance, and reliability for our clientele. Aside from the remote and on-site technical support and advice we provide, we also offer risk assessments of factories, machinery, and assembly lines. So, what does this look like? A risk assessment is broken up into sections, where one of our engineers takes a sequential approach in analysing the risks and hazards that present themselves on a worksite. Safety and risk requirements can be broken up into an index of Performance Level (PL), where risks are analysed based on their severity, frequency, and possibility of occurrence.    Risk assessments through Venus Automation are highly technical and are carried out by a Certified Electrical Safety Engineer, or CESE. CESE is a course/certification offered by Wieland; a company we work closely with as their Australian licensed distributor for electrical goods. This certification is globally recognised by SGS TÜV Saar, and covers the functional safety aspects of machinery with a focus on programmable electrical, electronic, and electro-mechanical aspects. Venus Automation offer risk assessments that are compliant with the training provided through the CESE certification, and is thus an operation that ensures that your factory machinery is legal, compliant, and most importantly, as safe as possible for operators and machinery alike.      This blog is an informative guide walking through how a risk assessment provided by a certified engineer such as this. This risk assessment comprises two machine lines that were assessed, where issues were found with a number of safety input devices, and power supply and connectivity methods. This blog post covers the corrections/suggestions that have been made to bring the safety rating of these devices up, and ensure that the plant machinery is compliant with safety standards, and Work Health and Safety Legislations and Acts.      Functional Safety Rating for Machines The problematic devices – introduction There were a total of seven different devices/situations that were found to not be of satisfactory compliance during this risk assessment. A brief outline of what these devices are has been listed below, with each of these problems – and their solutions – being discussed in their own sections on this post.    1. A single, non-safety contactor has been used, and operating current sometimes exceeds the contactor’s rated current. 2. All of the emergency stops for a machine are wired in single channels into a safety relay.  3. Upon checking with a multimeter, it has been found that the 24 Volt power supply sometimes drops to 20 Volts  4. Some of the machinery is connected via junction boxes, but this machinery has been propositioned to move between sides of the factory.  5. The emergency stop currently uses automatic reset, but operators require it to be manual reset.  6. There is a magnetic safety switch being used on a gate that requires locking, but it is intermittent in functionality, and is not secure enough.  7. There is no mechanical interlock being used on a gate that needs to be locked during hazardous machine operation.   Safety Contactors – requirements vs reality 0. Introduction Contactors are a vital part of connecting industrial machinery to 3 phase electricity. They receive power from relays when certain conditions are met; and when energised, a solenoid (a coil that acts an electromagnet) is powered and the contacts inside of it are pulled shut. Only when the contacts are shut will 3 phase power flow through the contactor and into the machinery that requires the electricity. Contactors can either be non-safety rated, or safety rated. Safety rated contactors come with auxiliary contact blocks: a set of usually 4 normally open or closed contacts that will change when the open/closed status of the contactor toggles. These can be used for feedback loops, which feed into the reset inputs of safety relays for the safe monitoring of the status of the contactor. When set up correctly (safely), safety contactor feedback loops will enable fault conditions to be met, and cause the discontinuation of machine operation. Safety contactors are often placed in series to one another, so that in the event of a contactor failing (which is discussed in potential hazards), the contactors will be able to still cut power to hazardous machinery.  Contactors become unsafe when they fail, and it is crucial that the machinery they power – and thus their respective power and current requirements – is suited to the ratings of what the contactor is capable of handling. Contactors can either be powering alternating current (AC) electrics, or a 24V power supply.  A Sprecher + Schuh Safety Rated, 7.5kw Contactor A Sprecher + Schuch Non-Safety Rated, 7.5kw Contactor 1. What we found During the plant assessment, analysis of the electrical panel revealed that there was one, non-safety rated contactor being used to provide 3 phase 415 Volt electricity to a 7.5 kilowatt, 12 Amp AC motor used in the plant. The contactor was rated for an amperage of 13 Amps, and a power maximum of 11 kilowatts. However, it was found that as the motor has aged, it has started drawing more and more amperage from the wall; so despite being equipped to handle the power requirements of the motor, the maximum current rating of the contactor is now exceeded by the current drawn by the motor.  What this means is that the contactor is now at risk of failure due to exceeded current draw.  2. potential hazards Due to their being only one contactor, if this contactor were to fail, there would be nothing preventing continuous flow of electricity from the grid to the motor; it would continue to operate indefinitely besides the main isolation switch. The contactor that was used had no auxiliary contacts, which means that feedback could not be monitored by a safety relay if required.    When amperage is exceeded beyond a contactor’s current rating, excess heat is generated and the normally open switches that are pulled shut by the energised solenoid can become welded shut. This means that power can flow continuously through the contactor, and cannot be stopped.  3. How to achieve category 4 To achieve a Category 4 safety rating with contactors, Venus Automation recommended that the single

Overview Safety Sensors & Switches September 26 2024 | Blog Post, Venus Automation Have you ever considered what keeps the powerful machines in our factories and workshops from becoming hazardous? In an age where automation and robotics drive efficiency, the critical role of safety switches and sensors often goes unnoticed. These devices are more than mere components; they are the guardians of our workplaces, standing watch over both equipment and personnel. Safety switches and sensors ensure that when something goes wrong, there’s an immediate response, minimizing the risk of injury and equipment damage. They operate quietly yet effectively, monitoring every movement and ensuring that each machine functions within safe parameters. Without them, the seamless operation of modern industrial processes would be at the mercy of human error and mechanical failure. In this blog, we will explore the various types of safety switches, including Enabling Switches, Position/Limit Switches, and Foot Pedal Switches. We’ll also delve into the realm of Safety Non-Contact Sensors, focusing on Inductive Proximity Sensors, Magnetic Coded Sensors, RFID Coded Sensors, and Stainless Steel Electronic Safety Switches. Join us as we uncover how these devices are not just components but essential elements of a safe and efficient industrial ecosystem. Safety switches : an overview Safety switches, also known as disconnect switches or residual current devices (RCDs), are essential components in electrical systems designed to protect people and property from electrical hazards such as electric shock and electrical fires. These devices are crucial for maintaining the safety and integrity of electrical installations across various applications, from residential settings to complex industrial environments. Safety switches serve multiple purposes: Fault Protection: They provide critical fault protection for motors and heavy machinery by monitoring electrical currents. If a fault is detected, such as a short circuit or an overload, the safety switch will automatically disconnect the power supply, preventing potential damage to equipment and reducing the risk of fire. Disconnecting Means: Acting as a reliable disconnecting means for service entrances, safety switches enable safe maintenance and servicing of electrical systems. They allow technicians to isolate electrical circuits before performing repairs or inspections, ensuring a safe working environment. Current Leakage Detection: Residual current devices (RCDs) specifically monitor the balance of electrical current between live and neutral wires. If an imbalance occurs, indicating potential leakage to the ground (which could lead to electric shock), the RCD will trip and disconnect the circuit within milliseconds. Enhanced Safety Features: Many modern safety switches come equipped with additional safety features such as manual reset functions, test buttons, and indicator lights that signal operational status. These features enhance user safety and facilitate easier troubleshooting and maintenance. Regulatory Compliance: Safety switches are often required by electrical codes and regulations to ensure safe electrical installations. Compliance with these standards not only protects individuals but also helps prevent costly damages and liabilities for businesses. By integrating safety switches into electrical systems, industries can significantly reduce the risk of accidents and create a safer working environment for employees. Their versatility and reliability make them indispensable in protecting against electrical hazards and ensuring the smooth operation of machinery. Types of Safety Switches Enabling Switch Position/Limit Switches Foot Pedal Switches Enabling Switches Enabling switches are critical safety devices designed to allow operators to control machines or processes in hazardous environments. These switches require continuous pressure to remain activated, offering a fail-safe solution if the operator releases the switch due to danger or discomfort. Often used in manual operation tasks like robot teaching or maintenance, enabling switches enhance safety by providing a controlled stop mechanism. They are typically three-position switches, offering multiple levels of control. DOLD – RE 6909 | Three Stage Enabling Switch Enabling switches EUCHNER ZSM Enabling Switch Euchner multi-function ZSM switch EUCHNER ZSB – Enabling Switch Euchner multi-button ZSB switch EUCHNER ZSA/ZSR – Enabling Switch Euchner single-button ZSA & ZSR switch ELFIN – 060P2MA | Two Hand Station Two-handed control station with button cutouts ELFIN – 060C2MA | Two Hand Control Station Two-handed control station SCHLEGEL – SZU_C002 | Enabling Switch Enabling Switch – SZU_C002: The SZU_C002 Enabling Switch from Schlegel ensures optimal safety in industrial…[+] Pizzato FD 2016-M2 Position switch with roller and stainless steel piston plunger The type FD 2016 position switch has metal housing in conjunction with the high degree of protection IP67 permits use under extreme ambient conditions. Pizzato FD 2031-M2 Position Switch with Roller Lever The type FD 2031 position switch has metal housing in conjunction with the high degree of protection IP67 permits use under extreme ambient conditions.. Pizzato FD 2056-M2 Position switch with adjustable length roller lever arm The type FD 2056 position switch has metal housing in conjunction with the high degree of protection IP67 permits use under extreme ambient conditions. Pizzato’s FD Series Safety Limit/Position switches play a crucial role in automation, serving as reliable safety devices. These position switches, designed by Pizzato, are widely installed in industrial machinery worldwide. Their versatility allows them to adapt to various configurations, making them essential components for ensuring safety in automated systems.   With a focus on safety, the FD series of position switches is engineered to withstand challenging environments. Featuring a robust metal powder-coated body, these switches achieve a high level of protection with an IP67 rating when combined with compatible cable glands. Pizzato’s FD Series Safety Limit/Position switches are indispensable safety devices that enhance automation systems, offering versatility, durability, and adherence to safety standards. What is a Foot Switch? A foot switch is a rugged electrical switch that can be activated by the simple application of foot pressure. It alters electrical contacts within a circuit when pressed. These switches are ideal for situations where hand-operated switches are inconvenient or pose safety risks. Their adaptability makes them suitable for a wide range of industrial needs. Why are Foot Switches Essential? Foot switches are an essential component in various industrial settings for several compelling reasons: Safety: In environments where operating machinery with hands could be risky, foot switches provide a safer alternative, allowing workers to maintain