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Machinery safety to suit every packaging machine scenario

Machinery safety to suit every packaging machine scenario
Following renewed risk assessments that led to an updated machine safety design concept for a servo-driven film wrapping machine, BVM Brunner now has the flexibility to meet a variety of customer needs whilst also ensuring the safety of machine operators.

BVM Brunner is a specialist manufacturer of film wrapping packaging machines. Having taken an early decision to comply with EN ISO 13849-1, BVM Brunner carried out renewed machine risk assessments in order to update the safety concepts on its machines. Following this, the company decided to implement a new safety design for one of its machines, which incorporated comprehensive, 'state of the art' safety solutions from Pilz. BVM Brunner's latest machine, the Compacta Genius Servo, is a fully automated machine with a continuous motion, cross-sealing jaw. A safety solution was required for this machine, which would not only safeguard the operator, but also complement the flexibility and easy handling required for processing a variety of products for different customers.

The Pilz Safety Calculator, PAScal, was used to determine the required PL and SIL (Safety Integrity Level) of the safety functions according to EN ISO 13849-1. The PL and SIL requirements, together with the handling requirements, were then matched with the Pilz product range within the PAScal Calculator library.

The new compact configurable safety relay, PNOZmulti Mini, was selected to monitor safety functions. Despite its compact 45mm width, the multi Mini with its 20 safe inputs and four safe semiconductor outputs (to SIL 3, PL e) covered all safety functions of the machine, including e-stop, light barriers and safety gates. The PC-based drag-and-drop PNOZmulti Configurator also minimised initial set up and enabled individual configuration for different customers and products.

The mechanical safety gate switches were replaced with low maintenance, non-contact magnetic safety switches, PSENmag, which offered high tolerances for set up and switching distance, a clearly visible status indicator and reduced engineering time due to plug in cables. Regardless of the size and complexity of packaging machines, there will often be a need for other safety-related components. Pilz offers a wide range of products, including safety switches, safety bolts, optoelectronic safety devices (light curtains), camera-based safety systems and emergency stop switches.

In order to maximise the productivity of packaging machines, high quality diagnostics are needed. Not only does Pilz offer a variety of operator displays that can convey relevant information to operators and maintenance engineers, but the company's PVIS 'intelligent diagnostics' technology provides plain text messages with precise information on the location of the fault, clearly defined responsibilities, as well as an integrated 'root cause' display. This ensures that production can be restarted quickly, minimising costly downtime.

Today, most packaging machines incorporate servo and motion control technology. The Pilz Motion Control (PMC) family covers motors, servo drives and motion controllers. The PMCprimo Drive, for example, combines the functions of a servo amplifier, motion controller and PLC in a single unit - with the added benefit of an integrated safe stop function. The new PMCprotego offers even more safety functionality, including safe reduced speed, safe operational stop and safe brake test.
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