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Systematic safety improvement in pneumatic systems

Training course

Presentation

DC-B/Levent Unan Systematic safety improvement in pneum. systems July 10, 2012

Outcome
After completing the course, the participant can:
1. Recognise the hazards in pneumatic processes
2. Analyse the risk factors of simple pneumatic designs
3. Implement safety measures and safety circuits
4. Improve the safety reliability of simple pneumatic designs

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1. General
During the designing stage of a machine,
we often face these questions:

• Is the machine still safe?

• Is it already unsafe?
• Is it dangerous?

The problem is that there is no universally valid definition of safety. Everyone who is involved with
a machine can interpret safety by his/her own perception. Although this conflict lies in the truth
that safety has no definition, there are standards that should be reached when certain levels of
safety are required.
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Safety Related Directives

Basic safety principles in the field of pneumatics: EN ISO 13849-2
1. Use of suitable materials
2. Correct dimensioning and layout
3. Energy isolation (exceptions are possible)
4. Pressure limiting
5. Limiting speed and similar parameters
6. Protection against unexpected start-up
7. Resistance to ambient conditions

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3. Operating modes
Initial position / Standstill
This position is where the machine is ready to operate and waits for a start signal from the operator.
As soon as the signal is received, the machine starts the required cycle. In this position, the
actuators are usually motionless. The risk at this mode is an unexpected start up of the machine, for
example when replacing a work piece.

Normal operation
In normal operation, the machine fulfils the required tasks. The movement of the actuators starts
after the start button is pressed. The operation may continue until a certain cycle is achieved or until
the stop button is pressed. The safety measures in this mode are:
•Collision avoidance
•Pressure limitation
•Two hand operations

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3. Operating modes
Set up and service operation
The machines are sometimes designed to achieve the same tasks with different materials or with
different production values. To change between the values, certain adjustments or component
changes need to be done at the machine. Consequently, the machine has to be stopped.

If the machine needs maintenance, raw material reloading, or in similar cases, the machine also
stops and does not operate. This kind of standstill requires a different approach than the initial
position stopping, as the machine should not start if the start button is pressed. And in many
cases, if the machine should be operated in such a condition, some safety aspects should be
triggered.
•Reduced forces
•Reduced speeds
•Plausibility checks
•Balanced forces at drive
•Two hand operation

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3. Operating modes
Emergency operation
This is an important operation mode as the word emergency refers to a state of danger. This mode
is used in cases where the operation of the machine endangers human life in various levels, the
product quality, the machine itself or the environment. The emergency operation requires special
attention because of its nature.

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4. Safe design of a packaging system

Hazardous areas
Now that we have chosen the components to design the system, we can think about the safety
aspects. We start by identifying the areas in the application which are hazardous for humans and
properties.

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4. Safe design of a packaging system

Risk spotting
After observing the movements of the piston, the dangerous areas can be spotted. Subsequently,
three hazardous zones are identified:
•When the lifting system goes up, you can clamp your fingers between the platform and the
upper conveyor
•When the lifting system goes down, you can clamp your fingers between the platform and the
lower conveyor
•When a box is lifted at a high speed, the box may fall and cause damage.

For these three zones, we prepare a risk analysis to clearly display the hazardous zones and
describe the consequences of an unsafe situation considering the operation modes.

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4. Safe design of a packaging system

Safety measures

In order to minimize the hazards of shearing, the system’s danger zone can be separated with a
safe guard, so that the no one can place their hands in these zones during the operation. This is a
safe design measure. Since there is a need for maintenance or retooling etc., the guard is
designed like a door so that the operators or the service personnel can carry out their tasks by
opening it whenever needed.

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5.1 Reducing speed

Extremely high speeds can occur in pneumatic systems due to the energy which is stored in the
compressed air. Incorrectly adjusted speed may have the following consequences:
•Personal injury
•Damage to the work piece
•Poor work piece quality
•Interference with work operations
•Excessive wear of the components

In order to avoid the consequences above, the right speed must be selected for each direction. The
speed of the pneumatic actuators is adjusted by throttling compressed air with the help of flow
control valves.

1 2
1 2

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5.1 Reducing speed

5.1.3 Exhaust and supply air throttling

1A1
m

1A1

m
1V3 1
1V3 1

2
2 The speed of a vertical cylinder with
1V2 2
1V2 2
a comparatively high load can be
adjusted in accordance with the
1 1 circuits shown on the left.
1V1 4 2 1V1 4 2

1M1 1M2 1M1 1M2

5 1 3 5 1 3

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5.1 Reducing speed

5.1.3 Exhaust and supply air throttling

1A1

1V3 1

1V2 2

1V1 2

1M1
1 3

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5.1 Reducing speed

5.1.3 Exhaust and supply air throttling

m
1A1

1V4 1 1 1V5 If the load is changing as seen in the example

(changing from pushing load to pulling load), both
sides of the cylinder should be equipped with
2 2

1V2 2 2 1V3
throttle valves which restrict both supply and
exhaust air to prevent the load acceleration.

1 1

1V1 4 2

1M1 1M2
5 1 3

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5.2 Reducing pressure

The supply air for a pneumatic application is taken from a compressed air distribution device. If
there is no specific distribution for a lower pressure value, the pressure on the distribution is usually
adjusted for the application which needs the highest pressure. However, it should be reduced for
various reasons:
•The high pressure generates high forces which may not be necessary in a specific pneumatic
application. Reducing this force reduces the risks concerning safety.
•High pressure is generated by compressing high volumes of air which increases the costs.
•Unnecessarily high pressure applies stress and reduces the lifetime of many pneumatic
components.
•High pressure compressed air causes more leakages.

Adjusting the right pressure plays an important role in safety and in costs as well as the product
quality.

A good and effective solution is to have various pressure sources such as “high” and “low” supplied
in the shop floor. This has a positive effect on the overall compressed air cost but, on the other hand,
the installation costs rise.
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5.2 Reducing pressure

In many pneumatic applications, the pressure is reduced by a pressure regulator. It may be a
single component or it can be in a part of the service unit. The pressure regulator can adjust the
required pressure, but the question is, what is the right pressure? A common answer to this
question is:
The minimum possible pressure to operate the system trouble free.

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5.2 Reducing pressure

1A1 2A1

1V1 4 2 2V1 4 2

1M1 2M1
5 1 3 5 1 3

0Z1 0Z2

3 bar

7 bar

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5.2 Reducing pressure

1A1 2A1

1V2 4 2 2V1 4 2

1M1 2M1
5 1 3 5 1 3

1V1
2
0Z1

1 3

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5.3 Stopping, holding and blocking a movement

The pneumatic actuators in an application carry a considerable amount of energy as they move and
they may potentially carry the same amount as they stand still. If not properly handled and controlled,
this energy may be harmful under certain circumstances. There are many cases where the actuator
should be stopped, held or blocked such as:
•Pushing of an emergency button
•Power failure
•Hose break
•Component failure
•During the initial mode
•During the maintenance mode

There are many possibilities to stop, hold or block a pneumatic actuator, depending on the application
and the risk of danger.

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5.3 Stopping, holding and blocking a movement

5.3.1 Mid-position closed direction control valve

a) Tahan tombol S1 silinder maju sampai maksimum

m
Tahan tombol S2 silinder mundur sampai minimum
1A1 Ketika tombol dilepas, berhenti pada posisi terakhir.

b) Tekan tombol S1 sesaat silinder maju sampai maksimum

Tekan tombol S2 sesaat silinder mundur sampai minimum
Ketika listrik padam, silinder berhenti pada posisi terakhir.

1V1 4 2

1M1 1M2
5 1 3

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5.3 Stopping, holding and blocking a movement

5.3.1 Mid-position closed direction control valve

This is the basic construction of a 5/3 mid-position closed valve. As seen, all the ports are
disconnected from each other at mid-position. Although they are closed, the air flow
between the ports is possible which may cause the load to move in the direction of gravity.

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5.3 Stopping, holding and blocking a movement

5.3.2 Pilot-operated check valves

The pilot operated check valves are used to hold a load from
moving. They provide much greater safety compared to a mid-
position closed direction control valve.

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5.3 Stopping, holding and blocking a movement

5.3.2 Pilot operated check valves

21
21

It is a check valve, which blocks the flow from 2 to 1.

The flow from 1 to 2 is always possible.

1 1

2
2
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5.3 Stopping, holding and blocking a movement

5.3.2 Pilot operated check valves

21
21

1 1

2
2

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5.3 Stopping, holding and blocking a movement

5.3.2 Pilot operated check valves

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5.3 Stopping, holding and blocking a movement

5.3.2 Pilot operated check valves

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5.3 Stopping, holding and blocking a movement

5.3.2 Pilot operated check valves
m
m
1A1
1A1

1V3 2 2 1V4
1V2 2 2 1V3

1 21 1 21
1 21 21 1

1V1 4 2 1V2 2
1V1 4 2
1M1 1M2 1M1
1M1 1M2 5 1 3 1 3
5 1 3

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5.3 Stopping, holding and blocking a movement

5.3.3 Clamping unit

Pneumatic cylinder movements can be pneumatically stopped and mechanically blocked. The
mechanical blocking of the cylinder is done by a clamping unit which is pilot air operated.

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5.3 Stopping, holding and blocking a movement

5.3.3 Clamping unit

Clamping unit, KP series

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5.3 Stopping, holding and blocking a movement

5.3.3 Clamping unit

If the clamping unit is pressurised, the clamps release the

piston rod against a spring.

If the clamping unit is depressurised, the clamps stick to the

rod by the spring force.

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5.3 Stopping, holding and blocking a movement

5.3.3 Clamping unit

1A1

1V4 2

1V3 1

1V1 4 2 1V2 2

1M1 1M2 1M1

5 1 3 1 3

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5.3 Stopping, holding and blocking a movement

5.3.4 Braking unit

Braking cylinder DNCKE

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5.3 Stopping, holding and blocking a movement

5.3.4 Braking unit

1A1

1V4 2

1V3 1

1V1 4 2 1V2 2

1M1 1M2 1M1

5 1 3 1 3

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5.3 Stopping, holding and blocking a movement

5.3.5 End position locking

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5.3 Stopping, holding and blocking a movement

5.3.6 Stop valves

1A1

1V3 2 1V4 2

1 1

1V1 2 1V2 4 2

1M1 1M1 1M2

1 3 5 1 3

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5.4 Two hand operation

1. Jika kedua tombol ditekan dengan beda waktu dibawah 0,5 s maka silinder akan mengepress.
Setelah sampai maksimum, silinder diam selama 2 detik
2. Setelah itu silinder mundur sampai minimum

(buat aplikasi ini secara pneumatik dan elektrik)

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5.5 Exhausting
When the solenoid is energised, the compressed air is directed into the pneumatic system from 1 to 2.
As soon as the solenoid is de-energised, the compressed air is exhausted immediately from 3.

Soft-start valve, MS-DE series

Soft-start valve, MS-DE series for category 4 requirements with 2-channel control

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5.6 Pressurising
p
100 %

50 %

t
t1

If the system has to be pressurised after it has been exhausted, this has to be done safely. The
components described in exhausting also have the function of safe pressurising. If an on/off valve has
the function of safe pressurising, it is are also called ‘soft start’ valve.

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5.7 Free of forces

In cases where the cylinder has to stop without being able to apply any force, the circuit has to be
designed according to this kind of safety function. Free of forces means, the piston rod does not apply
any force as long as the direction control valve is not triggered. To achieve this, the sum of the forces
acting on the piston should be zero. It should be kept in mind that this function can only be used in
applications where the load always remains constant.

F2

F1

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5.7 Free of forces

F2

F1

In the cylinder chamber above, the sum of the forces should be zero:
F1 = F2
P1 * A1 = P2 * A2

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5.7 Free of forces

1A1

1V3 2 2 1V4

1 1

1V1 2 1V2 2

1M1 1M1
12 82 1 3 12 82 1 3

0Z1

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5.7 Free of forces

In case of a piston through cylinder, there is no need to adjust the pressure as the piston areas on
both sides are equal. Therefore the sum of the forces are also equal.

1A1

1V2 2 2 1V3

1 1

1V1 4 2

1M1 1M2
5 1 3

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5.7 Free of forces

If the cylinder is vertically mounted with a constant load, the gravitational force must also be taken
into consideration.
1A1

F1

m
1V3 2 2 1V4

F2

1 1
1V2

G
1 3

1V1 4 2

F3 = m*g 1M1 1M2

F1 + F3 = F2 5 1 3

P1 * A1 + m * g = P2 * A2
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5.9 Maintaining pressure

In some cases there may be a pressure loss due to various causes which may cause a hazardous
situation. In such cases, due to the little or no pressure, the actuator may stop in an undesired
position, may not complete a cycle, may change the direction of travel due to the load or the load
may fall. These hazards should be considered and prevented by a technical solution.

1A1

1V1 4 2

1M1
5 1 3

1B1

Pressure sensor SDE1

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5.9 Maintaining pressure

Fungsi Pressure Switch yaitu :
1. Pressure Gauge Digital
2. Pressure Sensor

Type of Switching :
1. Threshold ( x >= .... Bar)
2. Windows Comparator ( ..... Bar < x < ...... Bar )

SP : Switching Point
HY : Hysterisis (+ % Tolerance)

Contact Output
NO : Normally Open
NC : Normally Close

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5.9 Maintaining pressure

1A1

1V2 4 2
If the supply pressure is lost, the system still has enough compressed
1M1 air for the required safety function.
5 1 3

1Z1

1V1
2

1
1B1

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5.10 Tamper-proof prevention of unexpected start-up

Persons may need to be in the danger zones to perform the following tasks (ISO 14118)
•Inspection
•Maintenance
•Manual loading/unloading
•Setting, adjustments
•Tool change
•Cleaning
•Lubrication
•Diagnostic, testing
•Minor repairs
•Work on power circuits
•Decommissioning
•Corrective actions

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5.10 Tamper-proof, prevention of unexpected start-up

This is a shut-off valve which shuts off the compressed air supply to the machine and exhausts the
remaining compressed air in the machine. When closed, the valve can be locked using a padlock.

This valve is designed to prevent unexpected start-up. It cannot be used as an emergency stop valve.

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6 Emergency stop
6.1 Definition

When a machine is designed, it is important to prevent (in order of priority):

•Hazardous conditions for people
•Damage to the machine
•Damage to the work piece

Due to the complexity of machines, there will always be hazards that cannot be foreseen or be
eliminated.

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6 Emergency stop
6.1 Definition
What should happen when the emergency stop is actuated?

Possible questions related to the emergency stop of a machine could be as follows:

•Is it safe to cut all the powers completely?
This may result in the free falling of an actuator with a load, which may increase the danger and
harm.
•Is it safe to stop the machine in position?
This may result in preventing the escape from a dangerous zone.
•Should some forms of power remain although the button is pushed?
•Is it required to brake or clamp the system?
This may additionally be required to stop the system in many systems
•Can the situation be worsened when machine is stopped?
•Should the actuator(s) move to a pre-defined position?
The answers to the above questions should be carefully examined and solved. They can be found in
the directive EN 13850 where the actions that the machine should do in emergency cases are
categorised.
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6 Emergency stop
6.2 Stop category 0
Uncontrolled stop: Any forms of power that are available in the machine are removed in less then
200 ms, brakes or mechanical stopping devices are applied.

6.3 Stop category 1

Controlled stop: The machine may still be harmful if the power is removed. The position of the
actuators should be changed to a safer position (for a trapped person or workpiece etc.) The
power in the machine is not removed until the actuator reaches a standstill position. (time-
delayed shut down of power supply).

6.4 Stop category 2

Controlled stop: The power to the actuators still remains although standstill position is achieved.
(Cooling pumps, fans etc.)
When the emergency stop is actuated, it usually triggers a safety relay which controls the desired
safety action. The resetting of the emergency stop must not allow the machine to a restart.

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8 Safeguards
Safeguards are necessary to provide operators with as much protection as possible from hazards that
may arise during machine operation.
Guard types
Fixed guards
Fixed guards are permanently attached to the machine. This type of safeguard is suitable when it is
unnecessary to remove the guard under normal operating conditions or when access is not required
during the work process. Examples would be chain covers or grilles in front of motor fans. They are
seldomly opened in order to carry out maintenance or retooling tasks.

Movable guards
If access is required to the danger zone during production (to feed a work piece or take away the
product, to feed raw materials), a movable guard can be used, e. g. a safety gate.
The frequency with which access is required determines whether the guard needs to be fixed or
movable. The standards can help you make this decision.
If the machine should be operated when the safety guard is opened, the system should trigger a safety
function. But if the machine needs to be operated, it should also operate regarding a safety function
again, such as reduced speed, reduced force etc.
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9 Electro sensitive protective equipment

9.1 Active optoelectronic protective devices (light curtains and laser scanners)

Safeguards of this type do not prevent access to a hazard, but detect a person or part of a person's
body when the person approaches the hazardous area.

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9 Electro sensitive protective equipment

9.2 Safe camera systems

The latest developments on the market are safe camera systems for monitoring configurable zones.
In contrast to simple sensors, they are able to record and analyse detailed information about the
whole monitored zone. This way, potentially hazardous work processes are safely monitored,
protecting man and machine.

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Basic safety tips for pneumatics

1. Always wear eye protection.
2. Read all pneumatic safety rules carefully and adhere to them.
3. Never aim compressed air directly at any body parts. Never aim the compressed air jet at your
own face or the faces of other persons.
4. Exhaust all circuits and components after use and make sure that they are pressure-free.
5. Never connect or activate a system which is under pressure without direct supervision of an
authorised person and/or without the explicit approval of a supervisor.
6. Never place yourself or any other person within the line of action of a pneumatic actuator or a
system component. This means that moving parts must never be aimed at another person.
Handle pneumatic components as if they were a loaded rifle.
7. Before activating a pneumatic system, make sure that you have examined all of its components
and are aware of what can happen when it is switched on.
8. Inspect and secure all attachments, fittings, compressed air piping, connectors and connections
before connecting pneumatic components or systems to compressed air supply.
9. Disconnect battery cables and exhaust compressed air supply lines before beginning adjustment,
maintenance or dismantling work at a pneumatic circuit.
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10. Make sure than no more than one person is in close proximity to a pneumatic system when it is
activated or deactivated.
11. The compressed air reservoir must never become hot.
12. Always use a regulator and a pressure gauge in your system in order to monitor its operating
conditions.
13. Never pressurise cylinders, reservoirs, directional control valves or other system components
with excessive pressure. The nominal pressure of a pneumatic component may never be
exceeded, because this almost inevitably leads to serious consequences.
14. Use only line-mounted valves, cylinders and regulators supplied by GEARS.
15. Maximum permissible pressure values must be adhered to for all products. Most commercially
available pneumatic components are laid out for operation in the 100 psi (7 bar) range. Ascertain
and be aware of the published layout and pressure specifications of the pneumatic components
which are supplied with the GEARS-IDS kit. Do not plan or set up any pneumatic circuits within
which the specified layout pressure is exceeded, and never allow the specified layout pressure to
be exceeded by pressure within a pneumatic component.

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