05 04 17 Sisemaq

Collaborative Robot Safety
SISEMAQ from 03rd to 5th of April in Sao Paulo / Brazil
KUKA Robotics Germany

Quality Department Standardization - Andr Hetzke
Collaborative Robot Safety | Andr Hetzke | 03.04.2017 | www.kuka.com Page: 1

Outline
HRC standards situation
Eliminating barriers Safety functions instead of fences
Examples of Applications
HRC standards situation
Which standard supports robot manufacturers and integrators?
ISO 10218
Industrial robots Safety requirements Part 1: Robots

Aimed at manufacturers of industrial robots
Instructions on how to ensure safety when designing and building an
industrial robot
Industrial robots Safety requirements Part 2: Robot systems and

integration
Aimed at system integrators
Instructions on how to ensure safety when integrating and installing an
industrial robot
To what extent is HRC already considered in ISO 10218?
ISO 10218 parts 1 and 2 only contain rough information about what
requirements collaborative robots and HRC applications are subject to.
Core message: The robot is only one component in a robot system and as
such is not sufficient for safe collaborative operation. The specified
application with collaborative operation must undergo a risk assessment.
There is no such thing as a safe robot. Only a safe application.
No human-robot collaboration is possible without a risk assessment.
The overall cell must always be considered (application, clamps,
gripper technology, robot,...).
What document describes HRC?
ISO/TS 15066:2016 Robots and robotic devices -- Collaborative robots
Technical specification in addition to ISO 10218 came out in February

2016.
No harmonized standard in Europe, however the intention is to include
it in ISO 10218.
The content is provisional and changes are possible due to new results
from research and practice.
Above all else, emphasis is placed on the significance of the risk
assessment for the entire application.
National plans to adopt ISO/TS 15066
U.S. has adopted as a Technical Report (TR), designation code TR R15.606-2016.
Singapore is in the process of adopting as an informative recommendation:
10218-1, -2 and 15066.
Japan has adopted the power and force limiting values as a regulation.
Japan was the first country that write instructions to the ISO/TS 15066, in
form of a guidance document
Germany has adopted as a national standard, designation code DIN ISO/TS
15066
UK has adopted as a national standard, designation code PD ISO/TS 15066
other countries may follow
Eliminating barriers
Safety functions instead of fences
Current situation: Automated mass production behind bars
In recent decades, robots have mainly been used in fully automated mass
production.
Due to the risks of

such systems, definite
borders were used in
the form of
safety fences!
In the environment of Industry 4.0 this is to develop further
The key aspects are:
Mass production tends to customized series production
Because of demographic changes the use of intelligent assistance
systems becomes interesting
Human operators are (again) more strongly integrated into production

processes. This changes the operating conditions and requirements for
robots.
The demographic changes
Quote from the final report of the Industrie 4.0 working group
It allows work to be organized in a way that takes

demographic changes and social factors into account.
Workers can focus on creative, value-added activities
since smart assistance systems can do the routine tasks.
In view of the impending shortage of skilled workers, this
will allow older workers to extend their working lives
and remain productive for longer.
This requires different safety principles for the use of robots.

The demographic changes
In February 2016, ISO published the initial version of
ISO/TS 15066. It refines the safety principles/safety
functions in ISO 10218-1 and -2 more precisely:
ISO/TS 15066:2016
Robots and robotic devices Collaborative robots
Safety-rated, monitored stop
Hand guiding
Speed
Implemented correctly, these new safety and
principles separation
enable collaborationmonitoring
between humans and robots
Power and force limiting by inherent design or

control
Why do we want HRC?
Humans and robots:
An ideal team due to the utilization of synergies
+ +
+ Strength Problem- + Creativity
Precision solving
approach
+ + Sensory
+ Endurance
+ capabilities
Flexibility
Speed
Evaluating these new functions (I)
Safety-rated, monitored stop
The technology exists. It is used, for example, at manual loading
stations for the handover of materials from/to the robot
Key modification compared to the past:
The drives of the robot can be active in a safety monitored stop while
the human operator is in his work area. The robot does not have to
be completely switched off
Once it has been ensured that all persons have again left the
workspace, Automatic mode can be resumed without further action
Evaluating these new functions (I)
Evaluating these new functions (II)
Hand guiding
The technology exists but is used relatively little today
Can also be used for larger robots
Besides hand guided subtasks, there can also be sequences running
automatically
The user controls and is responsible for manual movement of the robot
If the application also contains sequences running automatically, a
corresponding area safeguarded by safety fencing is required
Evaluating these new functions (II)
Evaluating these new functions (III)
Speed and separation monitoring
The components exist, further development is ongoing
Can also be used for larger robots
Different systems exist to measure the distance between human and
robot. They have however not really penetrated the market (e.g. safe
camera systems, capacitive proximity sensors)
Implementation is typically limited to slowing down or stopping the
robot if the distance becomes to small
Such systems, however, are only really effective once they are able to
influence the path planning of the robot and the robot can evade the
human operator
Evaluating these new functions (III)
In the following, we want to further examine the
fourth type of collaboration:
Power and force limitation
This is, for what robots especially designed for.

Since start of discussions on Collaborative robots in the Robot safety
ISO working group in 2004, this is the most intensively elaborared
collaborative method.
It was clear very early, that new functions were needed for this method
in order to ensure the safety of the human operator.
Unfortunately, a precise name was never given. While force limitation
can be clearly interpreted, the term power limitation is a bit
misleading. It refers to the limitation of the kinetic energy of the moving
mass.
The clear requirement of the ISO/TS 15066 is, that only specifically
designed robots may be used for this. They must have smooth surfaces
and may not have dangerous corners and edges. The same applies to
equipment like tools and grippers as well as to workpieces and the
remaining process environment.
Hazards resulting from immediate proximity to the robot:
Until now, fences separated humans from robots. If the fence is removed,
essentially two hazards arise:
Every application has unavoidable clamping points, e.g. where the
robot picks and deposits parts or process them. The technical
specification refers to this as quasi-static contacts
During robot motions in unobstructed space, human and robot can
collide this is referred to as transient contacts.
Of course, all other application risks and hazards must be assessed and
considered.
But those both shall be performed by safety functions of the robot.
What contact situations should be avoided?
Unintentional, unapproved contact situations should be avoided. This is
not always possible in HRC systems.
However, certain contact situations must not occur and must be ruled
out by designing the system in the appropriate manner:
Contact with sharp or pointed objects
Shearing contact
Contact with rough surfaces
Crushing situations involving the head region
As a general rule, motions at head or neck height should be avoided
Evaluating these new functions (IV)
Power and force limiting
The technology exists. The market is growing quickly.
Only feasible for robots especially designed for
Force limitation of transient contact (impact protection):
Limitation of the kinetic energy. Since the mass of the moving parts
is defined, the velocity of the moving parts must be safely limited
Force limitation of quasistatic contact (clamping protection):
If clamping of operator body parts is possible, the force generated by
the machine must be limited
In both cases, the contact area is very important: large, smooth
surfaces with no pin points and sharp edges
What types of contact are possible?
Free transient contact
Collision, bumping in free space
The robot touches a body part
A body part is pushed away or the person has the chance to
evade the robot.
Quasistatic contact
Crushing incident
A body part is crushed between a moving part of the robot and
another stationary or moving part of the cell
In any case, there must be an appropriate response after a contact situation to prevent any
further damage!
What factors have a relevant impact on the consequences?
Injury Type Velocity (V) Mass Collision object Body part
(M) (R) (K)
These factors determine the extent of the damage caused by contact.

The application already specifies certain framework conditions.
If the extent of the damage is increased by altering one factor, another factor
must be used to reduce the potential overall damage.
The first new safety function is thus the clamping protection.
It detects if someone has a finger at a potential clamping point. If so, the

protection is done by safely limiting the generated force to a maximum value
and release the clamped body part.
The limit value in reality is a maximum force per area, also called surface
compression or physical pressure.
For every body area, there is also a limit for the over all maximum
permissible force. This shall not be exceeded even if the surface is large.
In ISO/TS 15066, these limit values are described in table A.2 (please observe
entire Annex A!).
Clamping protection:
The second new safety function is the impact protection.
It detects if someone is in the path of the robot during motion in

unobstructed(!) space. The protection is done by safely limiting the
speed according to the mass being moved and stop the robot safely
when detecting a collision.
The limit value here also depends on the body region with which the
robot may collide with, and contact area.
In ISO/TS 15066, these limit values are described in table A.5 and Figure
A.4 (please observe entire Annex A!).
Impact protection:
How can HRC be implemented in stages?
Full automation Human-robot collaboration
Separated by a physical or No common workspace Working next to each Intended for collaborative,
optical safety fence intended other in a tight space is simultaneous work in a
possible common workspace
Contact with a moving Contact possible but
robot is not possible unlikely Spending time in the Contact intended
common workspace is only
intended on a sequential
basis
Contact is not intended,

but could well be possible
What safety level and safety functions may needed for HRC?
Collision detection
Force monitoring
PL d,
cat. 3 Space monitoring
Tool orientation monitoring
Velocity monitoring
Motion direction monitoring

How does an HRC application become safe?
Motion in free space
The application is safe!
Robot moves in defined area

Safe workspace monitoring
Robot stops upon undesired contact

Safe collision detection
Robot moves at suitable velocity

Safe velocity monitoring
Approach motions
The robot reacts in time to avoid incidents of

crushing
Robot observes the required velocity limit

Approach motions with a tool
The robot reacts in time to avoid incidents of

crushing
Suitable velocity limit defined for specific

situation
Robot observes the required velocity limit

How can the robot position be optimized?
The selection of an appropriate robot position should be taken into
consideration from the very start of system and process development:
Impact on contact situation
Undesirable contact situations can be avoided by choosing an appropriate
robot pose and path.
Impact on detection
The ability of the robot system to detect contacts using joint torque
sensors depends on the axis configuration
Lever arm
Number of sensors affected
Invalid force estimate near singular positions
How can the path be optimized?
The shorter the motions required to carry out a task, the lower the
probability of undesirable contact.
In order to control contact situations, path and orientation guidance

should be taken into consideration from the start and appropriately
determined. Examples:
Circumnavigate crushing hazards as much as possible
Reduce the risk of falling components
Transport as near to the ground as possible
Dragging guidance
How does dragging guidance work?
Direction of motion
Not in danger as the Not in danger as the

robot structure is dangerous tool is moved
moving towards him away from him.
rather than the
dangerous tool.
How does dragging guidance work?
Direction of motion
Not in danger as the Not in danger as the

padded side of the unsecured side of the
workpiece is moving workpiece is moving
towards him. away from him.
What must be taken into consideration in terms of grippers?
If the gripper can be reached by the human operator, there is a risk of
crushing between the gripper jaws:
Getting caught between the jaws is only permissible if the maximum
force of the gripper is less than the acceptable limit value for a finger
Otherwise: Prevent the insertion of fingers between the gripper jaws
through suitable design.
How do you identify a system with collaborative operation?
The standard requires the collaborative robots to be labeled with an appropriate
icon:
Examples of Applications
Examples
Examples
Examples
Examples
Examples
https://www.youtube.com/watch?v=OxNC8yvsZ6s
https://youtu.be/lx07e1l6SsQ
Thank You for your attention
Contact information
Andr Hetzke
Quality Management Standardization
KUKA Roboter GmbH
[email protected]
Tel. +49 821 797 4087
Collaborative Robot Safety | Andr Hetzke | 03.04.2017 | www.kuka.com Page: 49
PRACTICAL BENEFIT OF RISK ASSESSMENT:
ZONE DETERMINATION BY LAYOUT ANALYSIS
Chris Soranno / FS Expert (TV Rheinland, #282/17, Machinery)

Safety Standards & Competence Manager
SICK Produce & Competence Center of America (USA)
5 April 2017
YOUR SPEAKER
CHRIS SORANNO
SICK employee since 2014 (Industrial Safety Division)

Manager for Safety Standards and Competence
Regional Competence Center / Safety Americas
Certified Functional Safety Expert (TV Rheinland, #282/17, Machinery)
Expert Member in Technical Committees of
ISO ANSI RIA UL ASSE SPI
ISO/TC 199 Safety of machinery
ISO/TC 39 Machine tools
ANSI B11 Safety of machinery
Co-convenor ANSI B11.3 Power press brakes
Convenor ANSI B11.20 Integrated manufacturing systems
RIA Industrial & mobile robots
UL Industrial robots
ASSE Control of hazardous energy
SPI Plastics industry
PRACTICAL BENEFIT OF RISK ASSESSMENT: Zone Determination by Layout Analysis 2017 SICK, Inc. 2
SAFETY ZONES
WHAT IS A ZONE?
A zone may include space within or around the
system:
which is used by personnel to access a specific location,
an operating position or a servicing point;
in which personnel perform standard production
operations or other tasks.
TYPES OF ZONES
zone: a segmented space within a machine

control zone: An identified portion of a production
system under coordinated control
hazard zone: Any space within or around a
machine in which a person can be exposed to a
hazard in which an immediate or impending hazard
exists
task zone: Any predetermined space within or
around a machine in which a person can perform
work
Definition Sources:
ISO11161:2007, ANSI B11.19-DRAFT #8, ANSI B11.20 DRAFT #7
WHY CREATE ZONES?
Automation systems should be designed to
facilitate safe manual interventions
Set-Up Operation Troubleshooting Maintenance
For some manual interventions, it may be

impractical to stop the entire system
in which case the system should be segregated
into zone(s) where personnel can perform their
tasks safely
WHERE IS GUIDANCE AVAILABLE?
ISO 10218-2:2011 (ANSI/RIA R15.06-2012, Part 2)
5.9 Integrated manufacturing system (IMS) interface
5.9.1 General
5.9.2 Emergency stop
5.9.3 Safety-related parts of the IMS
5.9.4 Local control
5.9.5 Enabling device
5.9.6 Mode selection
5.9.7 Task zone implementation
WHERE IS GUIDANCE AVAILABLE?
ISO 11161:2007 + Amd 1:2010

Safety of machinery Integrated
manufacturing systems Basic
requirements
ANSI B11.20-2004 (R2015)
Safety Requirements for Integrated
Manufacturing Systems
INTERRELATIONSHIP OF STANDARDS
This figure describes the relationship of the scope of machinery standards used in a robot system
The robot alone is covered by Part 1, the system and cell is covered by Part 2
A robot cell may include other machines subject to their own C level standards, and the robot
system can be part of an integrated manufacturing system covered by ISO 11161 which in turn can
also make reference to other relevant B and C level standards
Part 2 adds additional information in line with ISO 12100 and ISO 11161
ISO 10218-1 ANSI/RIA R15.06
(Part 1)
Robot
ISO 10218-2 ANSI/RIA R15.06
Robot Other machine (Part 2)
system/cell (C-
(C-type) standard
ISO 11161 Integrated Manufacturing System ANSI B11.20
(IMS)
ISO 12100 RIA R15.306 & ANSI
RISK ASSESSMENT B11.0
Source: ISO 10218-2, Figure 1
INTERRELATIONSHIP OF STANDARDS
Image Source: ISO 10218-2, Annex B
INTEGRATED MANUFACTURING SYSTEMS
An integrated manufacturing system (IMS):
a) incorporates two or more industrial machines which:
1) can operate independent of each other, and
2) are intended for the purpose of manufacturing, treatment,
movement or packaging of discrete parts or assemblies;
b) is linked by a material handling system; and
c) is interconnected by a control system(s) for
coordinated operation Butt shear
Gate lock cylinder
(saw)
Platen
Die carrier
Image Sources:
ANSI B11.20 DRAFT #7
SPAN OF CONTROL
span of control: Predetermined portion of

the production system under control of a
specific device
The control of one or more control zones of

the machine by various safety-related control
devices is defined by the span of control of
each device
Definition Sources:
ISO 11161:2007, ANSI B11.19-DRAFT #8, ANSI B11.20 DRAFT #7
DEVICES WITH SPAN OF CONTROL
Typical safety-related control devices which

may have span of control include:
INPUT:
Safeguarding devices: Complimentary control devices:
o Interlock devices o Emergency stops
o Presence sensing devices o Enabling devices
o Hold-to-run controls
OUTPUT: o Resets
End switching devices:
o Contactors
o Valves
o Drives
SPAN OF CONTROL & LAYOUT ANALYSIS
Additional guidance in future machine-specific
(Type-C) ANSI standards:
The span of control of safety-related control devices shall
be determined by a layout analysis, which includes:
Specification of the limits
Task/hazard pairs as identified from a risk assessment
Task zone identification
Selecting risk reduction measures
Control zone identification
RISK ASSESSMENT PROCESS
Image Source: ANSI B11.0-2015, Figure 6 (Used with permission)

Referenced by RIA TR R15.306-2016, Clause 6
LAYOUT ANALYSIS PROCESS
Image Source: ANSI B11.20-DRAFT #7
COMPARISON OF PROCESSES
COMBINATION OF PROCESSES
Risk Assessment Process Layout Analysis Process
APPLYING LAYOUT ANALYSIS TO
AN EXAMPLE RISK ASSESSMENT
RISK ASSESSMENT EXAMPLE
PALLETIZING CELL
IDENTIFICATION OF TASKS
A: Load/Unload Pallets F2
B A B: Cleaning F1
C: Teaching Robot F1
D: Jam Clearing F2
E: Conveyor Maintenance F1
1) task: specific activity

performed by one or mor
e persons on, or in the
vicinity of, the machine
during its life cycle
2) task: Any specific

activity that is done with,
on or around the
machine during its
lifecycle.
D E D C B A
Definition Sources: 1) ISO 12100-1:2010
2) ANSI B11.0-2015
IDENTIFICATION OF HAZARD SOURCES
1: Robot / End Effector
2: Conveyor Lifts
3: Conveyors
hazard: A potential
source of harm
2 3 2 1
Definition Source:
ISO 12100-1:2015, ANSI B11.0-2015
IDENTIFICATION OF HAZARD TYPES
1: Robot / End Effector
Conveyor
2: 1a: CrushingLifts S3
Conveyors
3: 1b: Dropped parts S1
2: Conveyor Lifts
2a: Shearing S4
2b: Pinching S2
2c: Entanglement S3
3: Conveyors
3a: In-running nip points S2
2 3 2 1
IDENTIFY TASK ZONES
I: Load/Unload & Cleaning
I II: Teaching Robot
III: Jam Clearing
IV: Maintenance
task zone: Any

predetermined space within
or around a machine in
which a person can perform
work
III IV III II I
Definition Source:
ISO11161:2007, ANSI B11.19-DRAFT #8, ANSI B11.20 DRAFT #6
RISK ASSESSMENT: IDENTIFY TASK / HAZARD PAIRS
RISK ASSESSMENT: IDENTIFY TASK / HAZARD PAIRS
ROBOT CONVEYOR LIFTS CONV.

HAZARDS
1a 1b 2a 2b 2c 3a
TASKS Crushing Dropped Parts Shearing Pinching Entang.

Entang. In-
In-Running Nips
A L/UL 1 2 - - - - F2
B Cleaning 3 4 - - - - F1
C Teaching 5 6 - - - - F1
D Clearing 7 8 9 10 11 12 F2
E Maint.
Maint. 13 14 15 16 17 18 F1
S3 S1 S4 S2 S3 S2
RISK ASSESSMENT: RISK ESTIMATION
Haz- Sever- Exp- Avoid- Occur- Risk
ID Task PLr
ard ity osure ance rence Level
1 A 1a S3 F2 A1 O2 4 d
2 A 1b S2 F2 A2 O2 1 b
3 B 1a S3 F1 A1 O1 1 b
4 B 1b S2 F1 A2 O1 0 a
5 C 1a S3 F1 A1 O3 3 c
6 C 1b S2 F1 A2 O1 0 a
7 D 1a S3 F2 A1 O1 3 c
8 D 1b S2 F2 A2 O1 0 a
9 D 2a S3 F2 A2 O2 6 d
10 D 2b S1 F2 A2 O2 0 a
11 D 2c S2 F2 A2 O2 1 b
12 D 3a S1 F2 A2 O2 0 a
13 E 1a S3 F1 A1 O1 1 b
14 E 1b S2 F1 A2 O1 0 a
15 E 2a S3 F1 A2 O2 3 c
16 E 2b S1 F1 A2 O2 0 a
17 E 2c S2 F1 A2 O1 0 a
18 E 3a S1 F1 A1 O2 0 a
CONTROL ZONES FOR COEXISTENCE
Control Zone C
Control Zone A Control Zone B
APPLY PROTECTIVE MEASURES (GAP IN THE FENCE)
Safe!
But not very efficient
RISK REDUCTION MEASURES
R
R R
R R R
SAFETY-RELATED SPAN OF CONTROL
Control Zone C
R
R R
Control Zone A Control Zone B

R R R
RISK REDUCTION MEASURES
RISK ASSESSMENT: RISK REDUCTION MEASURES
Haz- Sever- Exp- Avoid- Occur- Risk Risk Reduction Measures:
ID Task PLr
ard ity osure ance rence Level Technical Protective Measures & Administrative Measures
Interlocked sliding door, Light curtain, Awareness light, Reduced robot speed controlled
1 A 1a S3 F2 A1 O2 4 d by Area scanner
2 A 1b S2 F2 A2 O2 1 b Interlocked sliding door, Light curtain
Interlocked sliding door, Light curtain, Awareness light, Reduced robot speed controlled
3 B 1a S3 F1 A1 O1 1 b by Area scanner
4 B 1b S2 F1 A2 O1 0 a Interlocked sliding door, Light curtain
5 C 1a S3 F1 A1 O3 3 c Teach pendant (with enabling device and emergency stop), Manual reduced speed (T1)
6 C 1b S2 F1 A2 O1 0 a Teach pendant (with enabling device and emergency stop), Manual reduced speed (T1)
Interlocked hinged door, Infeed light curtain, Interlocked sliding door, Emergency stop
7 D 1a S3 F2 A1 O1 3 c cable pull, Safe distance, Awareness signs
Interlocked hinged door, Infeed light curtain, Interlocked sliding door, Safe distance,
8 D 1b S2 F2 A2 O1 0 a Awareness signs
9 D 2a S3 F2 A2 O2 6 d cable pull, Safe distance, Awareness signs
10 D 2b S1 F2 A2 O2 0 a cable pull, Safe distance, Awareness signs
11 D 2c S2 F2 A2 O2 1 b cable pull, Safe distance, Awareness signs
12 D 3a S1 F2 A2 O2 0 a cable pull, Safe distance, Awareness signs
13 E 1a S3 F1 A1 O1 1 b Control of hazardous energy (lockout/tagout), Safe work procedures
14 E 1b S2 F1 A2 O1 0 a Control of hazardous energy (lockout/tagout), Safe work procedures
15 E 2a S3 F1 A2 O2 3 c Control of hazardous energy (lockout/tagout), Safe work procedures
16 E 2b S1 F1 A2 O2 0 a Control of hazardous energy (lockout/tagout), Safe work procedures
17 E 2c S2 F1 A2 O1 0 a Control of hazardous energy (lockout/tagout), Safe work procedures
18 E 3a S1 F1 A1 O2 0 a Control of hazardous energy (lockout/tagout), Safe work procedures
INTERACTION MATRIX
(PERFORMANCE LEVELS AND SPAN OF CONTROL)
SAFETY-RELATED COMPONENTS HIGHEST LEVEL OF SAFETY PERFORMANCE
FUNCTION DEVICE LOCATION ROBOT CONVEYOR LIFTS CONVEYORS
Light Curtain Conveyor Entrance d d b
Door Interlocks Lift Doors d d b
PROTECTIVE
Door Interlocks L/UL Doors d d b

STOP
Door Interlock Maintenance Door d d b

Light Curtains L/UL Stations d - -
Area Scanners L/UL Stations d - -
Position Switches Robot Primary Axes d - -
E-stop Pushbutton Conveyor Entrance b b b
EMERGENCY
E-stop Pushbuttons Lift Doors b b b

STOP
E-stop Pushbuttons L/UL Doors b b b

E-stop Pushbutton Maintenance Door b b b
E-stop Cable Pull Cell Interior b b b
Reset Pushbutton Conveyor Entrance d d a
Reset Pushbuttons Lift Doors d d a
RESET
Reset Pushbuttons L/UL Stations d d a

Reset Pushbutton Maintenance Door d d a
Muting Sensors Conveyor Entrance d d b
AUXILIARY
Mute Override Conveyor Entrance d d b

Awareness Lights L/UL Stations d - -
RISK ASSESSMENT: RISK REDUCTION MEASURES
Haz- RISK Risk Reduction Measures: Sever Exp Avoid Occur RISK
ID Task PLr
ard IN Technical Protective Measures & Administrative Measures ity osure ance rence OUT
Interlocked sliding door, Light curtain, Awareness light, Reduced robot speed controlled by
1 A 1a 4 d Area scanner
S3 F1 A1 O1 1
2 A 1b 1 b Interlocked sliding door, Light curtain S2 F1 A2 O1 0

Interlocked sliding door, Light curtain, Awareness light, Reduced robot speed controlled by
3 B 1a 1 b Area scanner
S3 F1 A1 O1 1
4 B 1b 0 a Interlocked sliding door, Light curtain S2 F1 A1 O1 0

5 C 1a 3 c Teach pendant (with enabling device and emergency stop), Manual reduced speed (T1) S3 F1 A1 O1 1
6 C 1b 0 a Teach pendant (with enabling device and emergency stop), Manual reduced speed (T1) S2 F1 A1 O1 0
7 D 1a 3 c cable pull, Safe distance, Awareness signs
S3 F1 A1 O1 1
Interlocked hinged door, Infeed light curtain, Interlocked sliding door, Safe distance,
8 D 1b 0 a Awareness signs
S2 F1 A1 O1 0
9 D 2a 6 d cable pull, Safe distance, Awareness signs
S3 F1 A1 O1 1
10 D 2b 0 a cable pull, Safe distance, Awareness signs
S1 F1 A1 O1 0
11 D 2c 1 b cable pull, Safe distance, Awareness signs
S2 F1 A1 O1 0
12 D 3a 0 a cable pull, Safe distance, Awareness signs
S1 F1 A1 O1 0
13 E 1a 1 b Control of hazardous energy (lockout/tagout), Safe work procedures S1 F1 A1 O1 0

14 E 1b 0 a Control of hazardous energy (lockout/tagout), Safe work procedures S1 F1 A1 O1 0
15 E 2a 3 c Control of hazardous energy (lockout/tagout), Safe work procedures S1 F1 A1 O1 0
16 E 2b 0 a Control of hazardous energy (lockout/tagout), Safe work procedures S1 F1 A1 O1 0
17 E 2c 0 a Control of hazardous energy (lockout/tagout), Safe work procedures S1 F1 A1 O1 0
18 E 3a 0 a Control of hazardous energy (lockout/tagout), Safe work procedures S1 F1 A1 O1 0
REVIEW
Process
1. The risk assessment process:
is used to reduce risks
is also used to more logically isolate / Risk Productivity
segregate various zones within complex
automation systems
2. Involvement of design engineers (systems,

controls, etc.) in the risk assessment
process is important in order to achieve
maximum safety and productivity
3. Other industrial safety standards can and

should be used for additional guidance to
maximize the results of a risk assessment
MANY THANKS FOR YOUR ATTENTION.
Chris Soranno / FS Expert (TV Rheinland, #282/17, Machinery)

Safety Standards & Competence Manager
SICK Produce & Competence Center of America (USA)
+1-216-513-8470
[email protected]
www.sick.com
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equipamentos de
trabalho h 24 anos
Somos Organismo de Inspeco acreditado e

Organismo Notificado N. 0464
EN ISO 12 100
Representao esquemtica de uma mquina
Sinalizao, Comandos manuais
Sistema de comando
visor, (rgos de servio)
avisos
Dispositivos de comando
Armazenamento de dados e processamento

digital ou analgico de dados
Sensores
Elementos de comando
Dispositivos de proteco
de energia
(contactores, vlvulas,
Parte operativa
controladores de velocidade)
Protectores Actuadores da mquina

(motores, cilindros)
Elementos de transmisso de energia

PARTES OPERATIVAS
Segurana dos sistemas oleohidrulicos
das mquinas
Segurana dos sistemas oleohidrulicos das mquinas
9 10 Aspectos relevantes
1. Sistema de comando
4
2. Seleco dos componentes
5
3. Presso
4. Resistncia mecnica
2 5. Movimentos mecnicos
1 6. Tubagem
7. Temperaturas
6
8. Ruido
10
3
9. Fludos
7 8 10. Erros de montagem/instalao
Conceber as partes dos sistemas de comando relacionadas com a segurana (SRP/CS)
conforme a EN ISO 13 849-1
PLr Risco
baixo
1. Parte do sistema de comando relacionada com a segurana (SRP/CS).

Funo de segurana: paragem do movimento de descida do cilindro.
2. Selector do modo de funcionamento
3. Bloco lgico/controlo
4. Sada de sinal de comando.
5. Actuador hidrulico (cilindro).
6. Input do sinal proveniente do protector de acesso zona perigosa
7. outut sinal proveniente de sensores de posio do cilindro.
Risco
elevado
Validao da
PL PLr ? SIM funo de

segurana
OK!
Agir sobre:
- Componentes aplicados para melhorar o MTTFd
NO - Arquitectura da SRP/CS melhorando a categoria
- Cobertura de diagnstico
Determinar o novo PL
2. Seleco dos componentes
ADVERTNCIA
SELEO IMPRPRIA, FALHA OU USO IMPRPRIO DOS PRODUTOS DESCRITOS NESTE
CATLOGO PODEM CAUSAR MORTE, DANOS PESSOAIS E/OU DANOS MATERIAIS.
(Este aviso consta da generalidade dos catlogos dos fornecedores de equipamentos oleohidrulicos)
Os componentes e as tubagens devem ser especificados e seleccionados de

modo a garantir a segurana global do sistema hidrulico em
funcionamento.
Deve ser dada especial ateno aos componentes e tubagem cuja falha ou
mau funcionamento possa por em causa a segurana do sistema hidrulico,
quando colocado em operao dentro dos limites de utilizao normal para
que foi concebido e fabricado.
Os componentes e a tubagem devem ser aplicados e instalados de acordo
com as instrues e recomendaes dos respectivos fabricantes.
vivamente recomendado, sempre que for praticvel, que sejam
especificados, seleccionados e aplicados componentes e tubagens em
conformidade com normas internacionais reconhecidas.
3. Presso
Soluo de preveno
Flutuaes recomendada:
de presso
no circuito
Aplicao de uma ou mais
vlvulas reguladoras de presso
Os riscos Presso localizadas nos pontos crticos do
devidos excessiva circuito
presso esto
associados a: Picos de Outros meios de compensao e
presso controlo adequados para manter
presso de servio do sistema
Perda de dentro dos limites estabelecidos
presso devem, sempre que se justifique,
ser aplicados.
Risco:
colapso da haste por falta de
resistncia mecnica Dimensionamento da haste (frmula de Euler)
PCR = Carga crtica
E = mdulo de elasticidade do material
I = Momento de inrcia da seco da haste
L = comprimento de encurvadura (flambagem)
L = K. h
D
h
As linhas a trao
interrompido mostram a
forma deformada da haste
sob a aco da carga
PCR
Para dimensionamento da haste, a literatura tcnica, recomenda

um coeficiente de segurana 5
Dimensionamento/seleco do cilindro
A espessura da parede do corpo determinante para a resistncia do cilindro
P presso interna.
Os fornecedores de equipamentos oleohidrulicos disponibilizam toda a informao
necessria e tabelas que facilitam a seleco dos cilindros adequados para operar de
acordo com as especificaes do sistema hidrulico que se pretenda instalar.
importante ter em conta, no s a presso de servio (P), mas tambm os picos de
presso que ocorrem, por exemplo, por aco da fora externa (F) imposta pelas
condies de trabalho a que o cilindro est sujeito.
Estes picos de presso podem atingir valores 3 a 4 vezes superiores presso de
servio (P).
A montagem e fixao dos cilindros tambm determinante para garantir a
resistncia mecnica nas condies de servio previstas. A m montagem e deficiente
F fixao dos cilindros pode induzir esforos de flexo e toro que no foram previstos
no seu dimensionamento e provocar o colapso.
Na instalao dos cilindros hidrulicos imperativo cumprir rigorosamente as
instrues do fabricante.
5. Movimentos mecnicos
ISO 4413; clusula 5.2.3 Movimentos mecnicos
Os movimentos mecnicos previstos ou imprevistos (p. ex. devidos a efeitos da acelerao, desacelerao
ou elevao/sustentao de massas) no devem resultar em situaes perigosas para as pessoas.
Movimentos mecnicos Imprevistos

Causa Consequncia Preveno
Deslizamento do mbolo
Fugas de leo Vlvula de reteno anti-retorno sada do cilindro.
por gravidade
Concepo e fabrico do sistema de comando de
acordo com a norma ISO 13 849-1. Determinao do
PL adequado.
Arranque Movimentos Isolamento automtico das fontes de energia e
intempestivo intempestivos do cilindro dissipao da presso acumulada:
- Bloqueio mecnico das vlvulas de reteno de
posio.
- Isolamento da alimentao de energia elctrica.
Rotura da tubagem Queda abrupta do cilindro Vlvula de reteno anti-retorno aplicada no
sada do cilindro por gravidade cilindro.
6. Tubagem rgida
ISO 4413; clusula 5.4.6 - Tubagem
As dimenses das tubagens e o respectivo layout
devem ser concebidos tendo em conta as velocidades
dos fludos, as variaes da presso e os requisitos de
arrefecimento, estimados para todos os pontos do
circuito hidrulico nas condies de funcionamento
previstas. Deve garantir-se que a velocidade, a presso
e a temperatura do fludo se mantm dentro dos
limites estabelecidos em todas as condies de servio
previstas. Dimenses (em mm) relativas ao espaamento entre suportes
CUIDADO
Antes da instalao, deve garantir-se que as
superfcies de vedao e as superfcies internas das
tubagens esto isentas de quaisquer objectos visveis,
estranhos e prejudiciais (partculas, rebarbas, etc. )
A presena destes objectos estranhos pode por em
causa a segurana do sistema hidrulico
Fonte: ISO 4413: 2010
6. Tubagem flexvel
ISO 4413, clusula, 5.4.6.5.2 Instalao:

Recomendaes par instalao
Na instalao de mangueiras flexveis deve

atender-se aos seguintes aspectos:
Aplicar o mnimo comprimento necessrio
para prevenir dobragens apertadas da
mangueira.
O raio de curvatura das mangueiras no
deve ser inferior ao recomendado pelo
fabricante
Evitar ou reduzir ao mnimo as
deformaes por efeitos de toro durante
a instalao e funcionamento
Localizar ou proteger as mangueiras de
modo a evitar danos no revestimento por
abraso
Sempre que o peso do conjunto das
mangueiras possa induzir esforos
indevidos devem ser suportadas por
dispositivos adequados
Fonte: ISO/TS 17165-2

6. Tubagem flexvel
Fonte: ISO/TS 17165-2

6. Tubagem flexvel
ISO 4413, clausula 5.4.6.5.2 - Proteco contra falhas

Quando a falha do conjunto da mangueira possa gerar riscos de projeco do

fluido e impacto por efeito de chicote, o conjunto de mangueira deve ser contido
ou blindado por meios adequados. Se tal no for possvel devido aos movimentos
pretendidos da mquina, devem ser fornecidas informaes sobre os riscos
residuais
Fonte: www.parker.com
7. Temperaturas
Riscos associados s temperaturas nos sistemas hidrulicos
Risco Consequncia Preveno
Manuteno da temperatura do fluido hidrulico dentro dos limites

estabelecidos.
Se mesmo assim a temperatura de algumas superfcies acessveis se
mantiver a cima do limites de segurana devem proteger-se ou, se no for
Contacto com superfcies
Queimadura possvel, aplicar-se avisos de perigo de contacto com superfcies quentes.
quentes
Estes avisos devem ser claros e indelveis.
Instalao de meios de controlo da temperatura do fluido hidrulico:

Alterao das Alterao da viscosidade do
caractersticas do fluido fluido Medio e controlo da temperatura no reservatrio de leo hidrulico.
hidrulico por efeito das Alterao da velocidade e Aplicao de dispositivos de medio e controlo da temperatura (ou de
variaes de temperatura caudal do fluido no circuito meios para os instalar sempre que necessrio) em pontos chave do circuito.
Permutadores de calor
8. Ruido
ISO 4413, clusula 5.4.5.2.2.2 - Vibrao e rudo
Devem-se tomar cuidados especiais para evitar vibraes e emisso de rudo areo, especialmente quando os
componentes so montados directamente no reservatrio
Rudo areo dos sistemas hidrulicos
Fonte Formas de minimizar a emisso de rudo areo
Adoptar velocidades de rotao da bomba to baicas quanto possvel.

Sempre que possvel, reduzir a presso e o deslocamento da bombas.
Aplicao de supressores , acumuladores ou atenuadores para reduzir o efeito
Unidade de energia (motor + bomba). das variaes de presso.
Movimentao de fluidos . Na instalao das tubagens devem evitar-se curvas apertadas (cotovelos).
Vibraes da estrutura do sistema Nos apoios e dispositivos de fixao das tubagens, sempre que se justifique,
hidrulico. devem aplicar-se materiais amortecedores.
Vibraes do reservatrio. Sempre que possvel devem evitar-se transies da tubagem metlica rgida
para mangueiras flexveis.
Se possvel usar tubagem com uma taxa de expanso volumtrica varivel
(acomoda melhor as vibraes).
9. Fludos
ISO 4413, 5.4.5.1 - Fludos
Os fludos devem ser especificados de acordo com as normas internacionais reconhecidas. O fabricante dos componentes ou dos
sistemas deve definir o fluido hidrulico apropriado pelo tipo e dados tcnicos ou, se tal no for possvel, pelo nome comercial do
fabricante do fluido hidrulico.
CUIDADOS A TER EM CONTA NA SELECO E ESPECIFICAO DOS FLUDOS HIDRULICOS:
A condutividade elctrica do fludo.
Se existir o perigo de incndio deve ter-se em ateno a resistncia ao fogo do fludo.
A compatibilidade do fludo com os componentes instalados no sistema hidrulico, nomeadamente:
Os acabamentos superficiais (pinturas) dos componentes
Processos e/ou fluidos utilizados na manuteno do sistema hidrulico
Dispositivos e materiais que possam vir a estar em contacto com o fludo hidrulico em caso de derrame como,
por exemplo, a cablagem elctrica.
O fluido hidrulico deve ser adequado ao componente do sistema mais sensvel contaminao. O grau de
limpeza do fluido deve ser especificado de acordo com a norma ISO 4406.
Ter em ateno que a informao comercial dos fluidos hidrulicos nem sempre refere o grau de limpeza,
quando so fornecidos.
Cuidado. A contaminao do fludo pode afectar a sua condutibilidade elctrica.
10. NA MONTAGEM E INSALAO DO SISTEMA HIDRULICO ESTEJA ATENTO, PELO MENOS, A:
Erros de O motor e as bombas so facilmente acessveis para manuteno?
montagem Os veios de transmisso esto correctamente alinhados?
e instalao Esto previstos meios para prevenir desalinhamentos dos veios devidos variaes de temperatura
e/ou esforos externos?
Os esforos axiais ou radias induzidos pela condies de servio s bombas, motores e outros
accionadores esto dentro dos limites estabelecidos?
Todas as unies das tubagens esto correctamente efectuadas?
Os veios das bombas rodam na direco correcta (marcada ou prevista)?
As bombas fazem circular o fludo hidrulico no sentido da admisso para a descarga?
Os veios dos motores rodam no sentido correspondente direco do caudal?
As vlvulas so facilmente acessveis para remoo, reparao ou regulao?
Existem meios e/ou procedimentos para evitar erros de montagem das vlvulas?
Existe espao suficiente para aceder aos parafusos de fixao e s ligaes elctricas das vlvulas?
Est montado um tabuleiro de reteno por baixo do reservatrio para suster o leo hidrulico em
caso de fuga ou derrame?
(o Anexo B da ISO 4413 contem uma lista de verificao exaustiva para registo de informao e controlo da conformidade com os requisitos desta norma).
Alberto Fonseca
Responsvel tcnico
[email protected]
www.catim.pt
Muito obrigado pela ateno
City of Porto
CATIM Centro de Apoio Tecnolgico Indstria Metalomecnica

Alberto Fonseca
SAFETY OF USED MACHINERY
COMPARISON BRAZIL & GERMANY
Otto Grnemann
Industrial Safety Systems
Product Marketing Services
2017 04 05
SAFETY OF USED MACHINERY
EUROPEAN DIRECTIVES MINIMUM REQUIREMENTS
Manufacturer Employer
TFEU
Treaty on the Functioning of the European Union
Art. 114 Art. 153
Removal of trade barriers within the EU Collaboration between EU members on
social issues
Low Product OSH Framework Directive 89/391/EEC
EMC Machinery
Voltage Safety Workplaces S&H signs PPE
Directive Directive 89/654/EEC 92/58/EEC 89/656/EEC
Directive Directive
2014/ 2006/
2014/ 2001/ Work equipment Ex. atmospheres
30/EUa 42/EC
35/EUa 95/EC 2009/104/EC 99/92/EC

National Law(s) National Law(s)
in each Member State in each Member State
(without changes) (higher national requirements allowed)
Otto Grnemann - SICK AG 10/2015 2

DIRECTIVE 89/391/EC
ARTICLES 5 + 6
General provision
1. The employer shall have a duty to ensure the safety and health of workers in every aspect
related to the work.
General obligations on employers
1. Within the context of his responsibilities, the employer shall take the measures necessary
for the safety and health protection of workers, []
The employer shall be alert to the need to adjust these measures to take account of
changing circumstances and aim to improve existing situations.

DIRECTIVE 89/391/EC
ARTICLE 16
Individual Directives
1. The Council, acting on a proposal from the Commission based on Article 118a of the
Treaty, shall adopt individual Directives, inter alia, in the areas listed in the Annex.
2. []
3. The provisions of this Directive shall apply in full to all the areas covered by the individual
Directives, []
ANNEX
- Work places
- Work equipment
[]
EMPLOYERS DUTIES
USE ACCORDING TO THE STATE OF THE ART VS. DESIGN
Operation acc. to the state of the art
OSH 89/391 EEC

Work equipment
Risk Maintenance Inspection
2009/104/EC Assessment
Employer
Putting into service
Substantial modification
Manufacturer
Machinery Directive Risk Risk Reduction Validation

2006/42/EC
Assessment
Design acc. to the state of the art

DIRECTIVE 2009/104/EC
ARTICLE 5
Initial inspection
After installation
Before first being put into service
Periodic inspections
Acc. to national laws
Special inspections
Modification work
Incidents
EMPLOYERS DUTIES
AIM TO IMPROVE EXISTING SITUATIONS
Maintenance
Improvemen
Servicing Inspection Repair
t
Definitions according to DIN 31051:2012

MODIFICATIONS & RETROFITTING
RISK ASSESSMENT AS A KEY
Function
(other) UVV
Performance ArbSchG
(more) (Work Safety Law) Used machine
n
Range of application
Substantial
modification
Intended use ?
(other)
y
Safety relevant ProdSG
devices (change) (Product Safety Law) New machine
Otherwise safety MD Employer Manufacturer!

relevant ?

SUBSTANTIAL MODIFICATION
INTERPRETATION BY THE GERMAN MINISTRY OF LABOUR & SOCIAL AFFAIRS

THE GERMAN WORK SAFETY ORDINANCE
BETRIEBSSICHERHEITSVERORDNUNG BETR.SICH.V
1. Scope and intention
2. Terms & definitions
3. Risk assessment
4. Obligations of the employers
5. Requirements for work equipment
6. Basic protective measures during the use of work equipment
7. Simplified procedure for the safe use of equipment General compliance
8. Protective measures against hazards derived form energy sources, starting & stopping
9. Additional protective measures for the safe use of equipment
10. Maintenance and modification of equipment
11. Special situations, malfunctions and accidents
12. Training employees and addressing tasks
13. Coordination of different employers (subcontracting)
14. Inspection of work equipment
15. Special provisions for high risk equipment (refer to Annexes )
RISK ASSESSMENT OG1
Before using work equipment, the employer has to assess the hazards (risk assessment) and the
necessary and appropriate protective measures.
The presence of a CE marking on the work equipment does not release the obligation to carry out a risk
assessment.
The assessment shall include all hazards arising from the use of work equipment, namely:
1. the work equipment itself,
2. the work environment and
3. the work items on which work is carried out with work equipment.
The following shall be considered in the risk assessment:

The suitability for use of work equipment, including ergonomic, age- and aging-oriented design,
The safety-relevant aspects, including the ergonomic interactions between workplace, work equipment, working
methods, work organization, work process, working time and work assignment,
The physical and psychological strain on the employees involved in the use of work
The foreseeable operational disturbances and the risk of taking measures to remedy them.
Slide 11
OG1 Otto Goernemann; 02/04/2017

OBLIGATIONS FOR THE EMPLOYER PROTECTION MEASURES
Work equipment may not be used until after the employer
has carried out a risk assessment,
the protective measures taken in accordance with the state of the art;
has established that the use of the work equipment is safe according to the state of the art
If the risk assessment reveals that hazards can not be adequately reduced by state of
the art technical protective measures , the employer
shall take appropriate organizational and personal protection measures.
Technical protection measures take precedence over organizational ones
Organizational measures have priority over personal protective measures
The use of personal protective equipment shall be limited to the minimum required for each
employee.
GENERAL COMPLIANCE
1. The employer may waive further measures pursuant to Sections 8 and 9 if the risk
assessment reveals that
1. the work equipment meets at least the safety requirements of the legislation applicable to them at
the time placing into the market,
2. the work equipment is used exclusively according to the specifications of the manufacturer,
3. no additional risks of the employees appear, taking into account the working environment, the work
pieces, the work processes, the duration and the part of the day of the working time, and
4. Maintenance measures according to 10 are taken and inspections according to 14 are carried
out.
2. Paragraph 1 shall not apply to installations subject to supervision and to the work
referred to in Annex 3.

CRIMINAL OFFENCE !
23 Crimes
1. Any person who is endangering the life or health of an employee by a deliberate act
referred to in Article 22 (1) is liable to prosecution pursuant to Article 26 (2) of the
Occupational Health and Safety Act.
2. Anyone persistently repeating a deliberate act referred to in Article 22 (2) or
endangering the life or health of another or foreign property of significant value by
such a deliberate act is punishable under Section 40 of the Product Safety Act.

ANNEX 1 ADDITIONAL REQUIREMENTS FOR SPECIFIC WORK EQUIPMENT
1. Specific rules for the use of mobile machinery (manned or unmanned)
2. Specific rules for the use of work equipment for lifting loads
3. Specific rules for work equipment used for occasional work on higher workplaces
4. Specific rules for Lifts
5. Specific rules for pressure work equipment

NR12 & BETRIEBSSICHERHEITSVERORDNUNG
COMPARISON (I)
NR12 Article Item BetrSichV
12.1 General Principles Signaling 3 to 6
12.6 Layout and facilities (other law)
12.14 Electrical installations and devices 9
12.24 Command devices for start, stop and control 8.3
12.38 Safety devices (Guards & protective devices) 4
12.56 Emergency Stop devices 8.6
12.64 Permanent access means 9.1.5
12.77 Pressurized components Annex 1 Part 5
12.85 Material handling General
12.94 Ergonomic aspects 3.2 , 6.1
NR12
COMPARISON (II)
12.106 Additional risks (other hazards) General

12.111 Maintenance, repairs, adjusting, commissioning, inspection 10
12.116 Signaling 9.5
12.125 Operating Instructions 3.4,
12.130 Work and safety procedures 4.6, 10.3
12.133 Design, manufacturing, import, sale, lease, making
available, auction, Exhibition, use MD
12.135 Technical training 12
12.148 Specific safety requirements 9 15 and
Annexes
12.153 Final provisions
NR12
COMPARISON (III) - ANNEXES > BGR / BGI RULES
I. Safety distances & requirements for the application of AOPDs
II. Operational training contents
III. Permanent access means
IV. Glossary
V. Power operated saws Different
BG
VI. Bakery Machines
Regulations
VII. Grocery and Butchering machinery
VIII. Presses & similar machinery
IX. Plastic injection machines
X. Shoe making and leather working machinery
XI. Machinery & equipment for agriculture & forestry
XII. Machinery & equipment for lifting persons and work at height
BGR / BGI RULES - EXAMPLE
DEVELOPMENT OF THE STATE OF THE ART MECHANICAL PRESSES
Required according to the MD
?
Level of Safety
Required according to the BetrSichV
Required according German law
VBG 7n VBG 7n5.1 VBG 7N5.1 VBG 7N5.1 VBG 7N5.1 EN 692 EN 692 EN 692 ISO DIS
04/1934 04/1957 4/1981 10/1987 01/1993 08/1996 01/2006 01/2008 16092-1
16092-2
NR12
RELATIONSHIP WITH STANDARDS
NR 12 references the following International or National Standards
EN ISO 13855 Positioning of protective Devices

EN ISO 14122 Means of access means to machinery
ABNT NBR 14153 or Safety related parts of control systems
EN ISO 138941-1
ABNT NBR NM-ISO 13852/13853 Safety distances for upper & lower limbs
(same content as EN ISO 13857)
ABNT NBR 13930 Mechanical Presses (Type-C Standard !) EN 692
EN 12622 Press Brakes (Type-C Standard !)
ANBT NBR 14631 Isolation classification
ANBT NBR 11900 Wire ropes, slings and terminations
THANK YOU FOR YOU ATTENTION.
Otto Grnemann
Product Marketing Services
Tel.: +49 7681 202 5420
[email protected]
CATIM, Centro de Apoio Tecnolgico Industria Metalomecnica
Dedicamo-nos
segurana de mquinas e
equipamentos de
trabalho h 24 anos
Somos Organismo de Inspeco acreditado e

Organismo Notificado N. 0464
Segurana de mquinas
em Portugal
Alberto Fonseca
CATIM, Portugal
A propsito de segurana de mquinas
Enquadramento legal da segurana de
mquinas em Portugal:
Mquinas novas
Mquinas usadas
A propsito da cultura de segurana de
mquinas
A propsito de segurana !!!
De que texto legal consta a seguinte clusula?

Se um construtor constri uma casa para algum e,
se por a construo no ser firme, a casa desaba
sobre o dono causando-lhe a morte, esse construtor
deve ser condenado morte.
1- Regulamento geral de 2- Cdigo de leis de
edificaes urbanas Hammurabi
3- Norma regulamentar 4- Regras tcnicas para

NR12 edifcios e pontes
A clusula consta do CDIGO DE LEIS DE HAMMURABI, telogo,
cientista, poltico e rei da Babilnia, que o escreveu h quase 4 000
anos (Sec. 18 a.c.).
A propsito de segurana de
mquinas !!!
SEGURANA
DE
MQUINAS
FUNCIONALIDADE
Conceito de segurana de mquinas (EN ISO 12 100):
Capacidade da mquina de desempenhar a sua funo (ou funes)
para que foi concebida durante todo o seu ciclo de vida para cujo risco
foi adequadamente reduzido
Segurana de mquinas em Portugal
Enquadramento legal
Segurana de mquinas e equipamentos de trabalho
Obrigaes legais
Fabricantes Utilizadores
Requisitos Essenciais de Requisitos Mnimos de

Segurana Segurana
DL 103/2008 de 24/06 DL 50/2005 de 25/02

(transpe par o direito nacional a Dir. Mquinas) (transpe para o direito nacional a Dir. Equip. Trabalho
COLOCAO NO MERCADO E/OU EM SERVIO

MQUINAS NOVAS
Mquinas colocadas pela primeira vez no mercado e/ou em servio no Espao Econmico Europeu
Procedimentos de avaliao da FABRICANTES DE MQUINAS

DL 103/2008 de 24/06
conformidade das mquinas (transpe par o direito nacional a Dir. Mquinas)
Processo Tcnico de Fabrico

Procedimento de controlo interno de fabrico
Mquina includa no no
Declarao de incorporao (quase-mquinas) ou
Anexo IV
? Declarao CE de Conformidade
sim
Marcao CE
Mquina fabricada sim

de acordo com as
N.E.H.s
?
no
ORGANISMO NOTIFICADO
Exame CE de Tipo ou Procedimento de garantia da qualidade total
MERCADO e/ou SERVIO

No fabrico de mquinas, a integrao da
segurana parece estar assumida
Descubra as diferenas
Na utilizao
a situao tende a melhorar ...
MQUINAS USADAS
Em servio ou para comercializao
UTILIZADORES Mquinas COMERCIALIZAO

Mquinas em servio de mquinas usadas
usadas
DL 50/2005 de 25/02 DL 214/95 de 18/08
Transpe para o direito nacional a Regula o comrcio de mquinas
Directiva Equipamentos de Trabalho usadas em Portugal
ORGANISMO Portaria 1772/2000 de 23/03

NOTIFICADO Regulamenta o DL 214/95.
Contm uma lista de, aproximadamente,
no Esto cumpridos os 70 mquinas utilizadas em vrios
requisitos mnimos de sectores industrias que devem ser
segurana do Anexo I submetidas a procedimento de
Do DL 50/2005 verificao da conformidade
? Responsabilidade do comerciante
Fornecer Manual de Instrues em
Portugus
sim Emitir a DECLARAO DO CEDENTE
COLOCAO EM SERVIO COLOCAO NO MERCADO

A propsito de cultura de segurana
de mquinas !!!
Power to the users.
Descubra as diferenas
One major player is often
neglected during the design
and procurement of work
equipment: THE USER. This
despite the fact that the
individuals who deal with
machinery and protective
equipment on a daily basis
are the very ones who could
provide manufacturers and
purchasers with valuable
information on how products
should be made safe and
user-friendly. More dialogue
leads to greater safety in
companies
KAN Brief, 4/12

de mquinas !!!
Incluir o pensamento intuitivo
Como no passado e, sem dvida, no presente, a segurana tal como a entendo, no futuro, deve
APRECIAO DO RISCO
incluir, para alm do que habitual, uma componente nova que direi feminina. Geralmente as
mulheres so por natureza mais intuitivas e capazes de se aperceberem dos perigos e riscos
possveis antes de os mesmos serem identificados por via da razo.
Esta maneira de pensar, que direi especfica das mulheres, no deve ser desqualificada e
descartada, como costume fazer-se, por supostamente serem muito prudentes, ansiosas e
portanto complicadas. ...
No h estatsticas precisas sobre o fenmeno mas os pediatras e as pessoas das urgncias
mdicas confirmam que as crianas e, particularmente os rapazes, criados por homens, ou
pelos seus pais, so mais propensas a acidentes do que as crianas criadas por mulheres, ou
pelas suas mes. um facto que a prudncia e o pensamento dirigido s fontes possveis de
perigo mais aguado nas meninas. Seria, no entanto, totalmente descabido insinuar que os
homens (falamos aqui particularmente dos europeus) so negligentes no seu trabalho, ou
acus-los de no cumprirem os seus deveres por falta de ateno.
Artur Doppelmayr, 1977
Rflexions Conceptionelles
Relatives lefficacit fonctionnelle des tlphriques monocbles
unidirectionnels
de mquinas !!!
Se sabe que uma coisa est

enterrada a 50 cm de
profundidade e j escavou
70 sem a encontrar:
Pare e v escavar noutro lado.
Edward de Bono
Fonte: INRS
de mquinas !!!
Proverbio chins:
Nem mesmo nove mulheres fsica, psicolgica e afectivamente
perfeitas conseguem dar luz um filho num ms
O conhecimento cientfico pode ser adquirido

em 3 anos.
Ex.: Automao e controlo.
A cultura e sobretudo as mudanas culturais

so processos mais longos e difceis.
Ex.: comportamentos de segurana
MUITO OBRIGADO PELA ATENO
Ponte Lus I, Porto
Alberto Fonseca
Responsvel tcnico
[email protected]
www.catim.pt
Segurana de mquinas
Uma viso Triparte
AFT Aida Cristina Becker
Coordenadora CNTT NR-12
So Paulo abril de 2017
CF /1988 - Art. 7 So direitos dos trabalhadores
urbanos e rurais, alm de outros que visem
melhoria de sua condio social:
XXII - reduo dos riscos inerentes ao
trabalho, por meio de normas de sade, higiene
e segurana;
http://www.planalto.gov.br/ccivil_03/constituicao/constituicaocompilado.htm
Prima em todo o seu corpo pela busca da plenitude do homem sem distines,
consagrando como valor a dignidade humana. Nesse sentido, observa-se a
afirmao do princpio da funo social da propriedade no corpo
constitucional, tanto no inciso XXIII do artigo 5, no mbito dos direitos e
garantias fundamentais, quanto no inciso III do artigo 170, como essncia da
ordem econmica, a qual visa assegurar a todos existncia digna.
A funo social da empresa, assim, surge combinada com aes sociais, inspiradas em
direitos nobres, como a tutela do meio ambiente natural ou artificial, melhoria do
meio ambiente de trabalho e das relaes entre empresrio e empregados. A
atividade empresarial deve atender no s a interesses individuais, mas tambm os
interesses gerais da sociedade de consumo, de forma que haja um equilbrio
(FERREIRA, 2005).
CLT 1943 Ttulo II - Seco III Segurana do trabalho
Art.192. As partes moveis de quaisquer
mquinas ou os seus acessrios (inclusive
correias e eixos de transmisso), quando ao
alcance dos trabalhadores, devero ser
protegidas por dispositivos de segurana
que os garantam suficientemente contra
http://www.tst.jus.br/legislacao?p_auth=5NBo3AYt&p_
p_auth=7ugTymtb&p_p_id=20&p_p_lifecycle=1&p_p_s
qualquer acidente.
tate=exclusive&p_p_mode=view&_20_struts_action=% http://www2.camara.leg.br/legin/fed/declei/1940-1949/decreto-lei-5452-1-maio-1943-415500-
2Fdocument_library%2Fget_file&_20_groupId=10157& publicacaooriginal-1-pe.html
_20_folderId=3600569&_20_name=14816
NR 12 - Mquinas e Equipamentos (1978)
12.2.2. - As mquinas e os
equipamentos com acionamento
repetitivo, que no tenham proteo
adequada, oferecendo risco ao operador, devem
ter dispositivos apropriados de segurana para
seu acionamento.
http://www010.dataprev.gov.br/sislex/paginas/63/mte/1978/3214.htm
2000/2001 Diagnstico para priorizao de estratgias de reduo
de acidentes, estudo Ministrio da Previdncia Social Mquinas
e Acidentes de Trabalho (serie volumes da previdncia social n
13), que identificou, dentre as mquinas que mais causam
acidentes, as prensas para metalurgia, responsveis por 42% dos
casos de esmagamento de dedos ou mos registrados em 1995 e
25% de todos os acidentes graves causados por mquinas no
mesmo ano. Grande parte desses acidentes ocorreu em razo da
utilizao de mquinas obsoletas e inseguras, incrementando as
despesas pblicas com a previdncia e sade.
http://www.previdencia.gov.br/arquivos/office/3_081014-111357-
Plano Nacional de Segurana e Sade
no Trabalho (PNSST)
O Decreto 7.602/11 estabelece a Poltica Nacional de
Segurana e Sade no Trabalho onde os ministrios do
Trabalho e Emprego (MTE), Previdncia Social (MPAS) e Sade
(MS) desenvolvem plano conjunto com a finalidade de
integrar as aes de melhoria da qualidade de vida do
trabalhador e a preveno de acidentes e danos sade
relacionados ao trabalho.
I - A Poltica Nacional de Segurana e Sade no Trabalho -
PNSST tem por objetivos a promoo da sade e a melhoria
da qualidade de vida do trabalhador e a preveno de
acidentes e de danos sade advindos, relacionados ao
trabalho ou que ocorram no curso dele, por meio da
eliminao ou reduo dos riscos nos ambientes de trabalho;
II - A PNSST tem por princpios:
a)universalidade;
b)preveno;
c)precedncia das aes de promoo, proteo e
preveno sobre as de assistncia, reabilitao e reparao;
DIRETRIZES
IV - As aes no mbito da PNSST devem constar do Plano Nacional de Segurana
e Sade no Trabalho e desenvolver-se de acordo com as seguintes diretrizes:
a)incluso de todos trabalhadores brasileiros no sistema nacional de promoo e
proteo da sade;
...
VI - Cabe ao Ministrio do Trabalho e Emprego:
b)elaborar e revisar, em modelo tripartite, as Normas Regulamentadoras de
Segurana e Sade no Trabalho;
e) acompanhar o cumprimento, em mbito nacional, dos acordos e convenes
ratificados pelo Governo brasileiro junto a organismos internacionais, em especial
Organizao Internacional do Trabalho - OIT, nos assuntos de sua rea de
competncia;
Conveno 144 OIT Consulta Tripartite
Portaria n. 393, de 09 de abril de 1996,

Instaura a participao tripartite no
processo de reviso ou elaborao de
regulamentaes na rea de segurana
e sade no trabalho e de normas gerais
relacionadas s condies de trabalho.
GTT GRUPO TCNICO TRIPARTE NR12 Objetivos principais:
Trazer informaes sobre boas prticas em segurana de mquinas;
Nova gerao de mquinas : Concepo com segurana intrnseca
da mquina ;
Adequao das mquinas existentes;
Reduo das assimetrias regionais quanto a proteo dos
trabalhadores;
Reduo dos acidentes tpicos;
Preveno de doenas.
GT (texto base) Portaria n 56 de 19/6/2008
2009 - elaborao do
GET (tripartite) texto para consulta
pblica
Portaria n 108 de
26/08/2009 - Consulta Pblica
recebimento de
sugestes por 60 2010 - apreciao
dias GTT (tripartite) das sugestes e
redao do texto final
Setembro/2010
aprovao NR 12 e do CTPP (tripartite)
item 31.12 da NR31 ATA n62
NR12 (Portaria n 197 de 17/12/2010 D.O.U. em 24/12/2010)

CNTT NR-12 - tripartite
8 Portarias
+ 2 Portarias aprovadas na
CTPP aguardando publicao
5 NT
NT rob aguardando publicao
IN procedimento especial de fiscalizao para

NR-12 (NT n2 e NT n55)
http://www.trabalho.gov.br/seguranca-e-saude-no-trabalho/normatizacao/normas-regulamentadoras/norma-regulamentadora-n-12-
seguranca-no-trabalho-em-maquinas-e-equipamentos
Dados: MTB/ CAT/SFIT
8 AT/h com mquinas:

35 fraturas/dia

11 amputaes/dia

1 bito a cada 2 dias
AT fatais +AT c/afastamento= 16.000
Aes Fiscais
17.100
15.428
13.852
13.101
12.058
11.491 11.115
10.444 10.511
8.957
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
Dados: MTB/SFIT
Dados: MTB/ SFIT
Interdio/Embargo (eventos)
2.109
1.707 1.690
1.313
1.093
742 743 735
569 502
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
10 % das aes fiscais e dos AT fatais +AT C/ afastamento
Os 10 mais autuao/interdio

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What are the main standards discussed for ensuring safety of collaborative robots?

What are the main standards discussed for ensuring safety of collaborative robots?

What document specifically describes requirements for human-robot collaboration?

What document specifically describes requirements for human-robot collaboration?

Collaborative Robot Safety

SISEMAQ from 03rd to 5th of April in Sao Paulo / Brazil

KUKA Robotics Germany

Collaborative Robot Safety | Andr Hetzke | 03.04.2017 | www.kuka.com Page: 1

Industrial robots Safety requirements Part 1: Robots

Industrial robots Safety requirements Part 2: Robot systems and

Technical specification in addition to ISO 10218 came out in February

Due to the risks of

Human operators are (again) more strongly integrated into production

It allows work to be organized in a way that takes

This requires different safety principles for the use of robots.

Power and force limiting by inherent design or

Power and force limitation

This is, for what robots especially designed for.

These factors determine the extent of the damage caused by contact.

It detects if someone has a finger at a potential clamping point. If so, the

It detects if someone is in the path of the robot during motion in

Contact is not intended,

Tool orientation monitoring

Motion direction monitoring

Robot moves in defined area

Robot stops upon undesired contact

Robot moves at suitable velocity

The robot reacts in time to avoid incidents of

Robot observes the required velocity limit

The robot reacts in time to avoid incidents of

Suitable velocity limit defined for specific

Robot observes the required velocity limit

In order to control contact situations, path and orientation guidance

Not in danger as the Not in danger as the

Not in danger as the Not in danger as the

Chris Soranno / FS Expert (TV Rheinland, #282/17, Machinery)

SICK employee since 2014 (Industrial Safety Division)

zone: a segmented space within a machine

Set-Up Operation Troubleshooting Maintenance

For some manual interventions, it may be

ISO 11161:2007 + Amd 1:2010

Source: ISO 10218-2, Figure 1

Image Source: ISO 10218-2, Annex B

span of control: Predetermined portion of

The control of one or more control zones of

Typical safety-related control devices which

Image Source: ANSI B11.0-2015, Figure 6 (Used with permission)

Image Source: ANSI B11.20-DRAFT #7

Risk Assessment Process Layout Analysis Process

1) task: specific activity

2) task: Any specific

task zone: Any

ROBOT CONVEYOR LIFTS CONV.

TASKS Crushing Dropped Parts Shearing Pinching Entang.

Control Zone A Control Zone B

Control Zone A Control Zone B

2 A 1b S2 F2 A2 O2 1 b Interlocked sliding door, Light curtain

4 B 1b S2 F1 A2 O1 0 a Interlocked sliding door, Light curtain

13 E 1a S3 F1 A1 O1 1 b Control of hazardous energy (lockout/tagout), Safe work procedures