Overview of services




 

Status check "CE marking of machines"

Your requirement

As a manufacturer, you must create the documentation according to the requirements of the machinery directive during the construction of machines. The completeness of the documentation and compliance with the relevant standards is to be observed here. You provide confirmation of this by means of the Declaration of Conformity and CE marking. As an operating company, you must have the original operating instructions to create the hazard assessment.

Our solution

We check the compliance of the requirements from the machine for

  • the Declaration of Conformity/Declaration of Incorporation and the CE marking
  • the original operating instructions and requirements for safety
  • the design of the safe part of the control on the basis of the relevant EU standards
  • the machine documentation

Creation of a detailed report on the status of the documentation

Your advantage

  • Independent examination of the scope of the documentation according to the requirements of the machinery directive
  • Recommendations for correction in the event of possible deviations

 

Risk assessment

Your requirement

The risk assessment is used to identify hazards on industrial machines and to minimizes those hazards through suitable measures. It is, thus, an essential prerequisite for the safe operation of machines. The risk assessment is also necessary for the conformity assessment in accordance with the relevant directives, such as the European machinery directive. It is generally a fixed part of the development process of a machine. A risk assessment is also necessary in the case of significant modifications or extensions of machines.

Our solution

  • Analysis of the existing risks
  • Assessment of the existing risks and calculation of a risk value with HaRMONY
  • Description of the risk-minimizing measures
  • Verification of the effectiveness through re-assessment of the risks after applying the risk-reducing measures

Your advantage

  • Use our many years of experience in the creation of risk assessments
  • Tailored solutions: from targeted support to complete execution

 

Conformity assessment in accordance with the machinery directive

Your requirement

If a machine is placed on the European market, a conformity assessment must first be performed. Machinery Directive 2006/42/EC defines the procedure here. The manufacturer confirms compliance with the specifications from the directive through the Declaration of Conformity and the CE marking. We support you with the compliance and implementation of the legal specifications.

Our solution

  • Tailored support over the entire process
  • Examination of the project state thus far for content and completeness, e.g., with regard to risk assessment, design and documentation
  • Suggestion for the content of the Declaration of Conformity

Your advantage

  • Independent confirmation of compliance with the requirements of the machinery directive
  • Recommendations for correction in the event of possible deviations

 

Safety concept and design

Your requirement

The measures necessary for risk minimization are known from the risk analysis. The design engineer develops the safety concept on the basis of these requirements. The required safety functions are to be designed here so that an optimum balance between safety, ergonomics and cost effectiveness is achieved while taking into account the relevant standards and regulations. Also important is the proper documentation of the safety functions. In the validation plan, the function and error tests are defined that verify the effectiveness of the safety functions during commissioning.

Our solution

  • Development of practically oriented concept suggestions
  • Selection of suitable components and creation of the connection plan
  • Programming of the safety-oriented part of the control
  • Clear and understandable documentation of the safety functions
  • Creation of the validation plan

Your advantage

  • Proper procedures ensured during the implementation of safety functions
  • Optimum safety concepts through our extensive industry knowledge and many years of safety-related experience
  • Avoid design errors through external qualification

 

Verification and validation of safety functions

Your requirement

To avoid errors during the implementation of safety functions, the correct and complete design of the safety functions is to be verified. This is performed on the basis of the requirements from the specification and applies for both the software and the hardware implementation. The performance of the safety functions is then to be validated through function tests and error simulations. The steps necessary for doing this are defined in the validation plan already during the design phase.

Our solution

  • Tailored support during the entire process
  • Examination of the current project state for content and completeness
  • Planning and execution of individual process steps, e.g., definition of the function tests and creation of the corresponding documentation

Your advantage

  • Proper procedures ensured during the implementation of safety functions
  • Efficient implementation of the necessary tasks through support and tips from experienced experts

 

Start-up support

Your requirement

During the commissioning or exchange of safety sensors, tasks such as optimum alignment and configuration are to be performed. The necessary information and procedures are described in the respective operating instructions. The goal is fast and safe commissioning. Should a device need to be replaced, the downtime of the machine should be minimized.

Our solution

  • Optimum alignment of optical sensors
  • Support during configuration or selection of the operating mode or configuration of protective fields for laser scanners
  • Adaptation of the configuration when changing to a newer device generation
  • Help during troubleshooting, e.g., device selection or wiring

Your advantage

  • Fast and safe commissioning by our service technicians
  • Calculable costs
  • Minimum downtime in the case of a device exchange

 

Inspection of protective devices

Your requirement

Safety at work is the employer's responsibility and, therefore, the "boss's business". Through the regular inspection of the protective devices, adherence to safety and quality standards is ensured. As part of the preventive maintenance plan, inspections minimize undesired machine downtimes. In Germany, the Ordinance on Industrial Safety and Health also requires testing of the machines. A test is to be performed prior to the initial commissioning of the machine and then at regular intervals. A test is also necessary after longer downtimes and after changes to the machine. The testing and inspection of protective devices may only be performed by competent persons.

Our solution

  • Inspection of electro-sensitive protective equipment (ESPE), safety switches and emergency stop equipment
  • Checking of the condition, of the functional attachment and of the correct function of the protective device as well as of the safe integration in the machine control
  • We recommend checking the necessary safety distance to the point of operation by measuring the stopping time
  • Detailed test log, attachment of the inspection sticker

Your advantage

  • Minimization of accident risks and machine downtime
  • Legal security for the operating company through verification of safety and quality standards
  • Practically oriented solution proposals for the rapid rectification of safety deficiencies

On request, we also perform inspections for protective devices from other manufacturers.


 

On-site at your location

Collect data - test integration

The inspection begins with the collection of data from the machine and protective devices. We then test the safety-related integration of the protective devices and their switching outputs.
This work is conducted during operation without affecting the productivity of the machine. 

Checking protective devices

In the next step, we test the function of the protective devices.
For optical safety devices, this includes e.g.:
— Testing of the detection capability and possible reflection bypass. Testing is performed with a test piece that is matched to the resolution of the device.
— Testing of special functions such as reduced resolution, cycle control, muting and blanking
— Testing operation of the start/restart interlock
— Visual inspection of the device state

Evaluate mounting and safety distance

We check that the protective device is mounted correctly, and assess the safety distance:
— Can the protective device be circumvented, e.g. by reaching over, under or around or by stepping over?
— Is it possible to crawl under the protective device?
— Measurement of the stopping time for determining the safety distance (if necessary and possible, see next page).

Log test results – attach inspection sticker

We record all results in the inspection database and use this information to create a clearly organized test log. On completion of the inspection, we attach the inspection stickers to the machine, which also include the inspection number of the test log to simplify tracking.


 

Stopping time measurement

Your requirement

Only through a sufficiently dimensioned safety distance between protective device and point of operation is it ensured that persons are not endangered. To calculate the necessary safety distance, the stopping time of the machine is to be determined through measurements. The protective device can thereby be correctly placed.

Wear can extend the stopping time of machines in such a way that reliable protection of the operator is no longer ensured by the protective device. Possible causes include, e.g., defective brakes or faulty spark extinction circuits. The stopping time measurement is therefore part of the regular safety inspection with us.

Our solution

  • Physical test of the stopping time for all installed protective devices with calibrated measurement devices
  • Assessment of the safety distance based on the test results and the requirements in accordance with EN ISO 13855:2010
  • Comprehensible and well-documented test results in accordance with DIN ISO 9001:2015 and optional graphic analysis of the braking motion

Your advantage

  • Propagation time measurements performed by experts provide a safe and sound basis for positioning the protective device
  • Regular inspection enables early detection of wear, thereby ensuring permanent machine safety

 


 

On-site at your location

Determination of the stopping time with special measurement device

The stopping time is determined with a special measurement device.
This measures the time from the interruption of a protective device until the dangerous movement comes to a standstill:
— An actuator (automatic hand) is mounted on the protective device – e.g., a safety light curtain – that triggers the protective device
— A rope length sensor detects the movement of the machine. This allows the time until the hazardous movement stops to be determined.
— The measurement is performed at the maximum speed of the movement if possible

Evaluation of the results

In accordance with the requirements of the standard ISO 13855, we conduct ten measurements in succession. The largest value from this series of measurements is then documented as the result for the stopping time and used in assessing the safety distance.
A graphical analysis of the braking movement is also available as an option if necessary.


 

Status check "Safety technology on machines and systems"

Your requirement

As an operating company, you are responsible for the safety of your machines. Over time, changes, extensions or wear affect the condition of the machines and of the used protective devices. A "reliable" overview of the condition of the machinery is necessary to determine possible needs for action with respect to the safety of the machines.

 

Our solution

  • Our experts perform the professional identification, description and assessment of existing risks for mechanical hazards on your machines and systems
  • The current situation is recorded by means of an on-site inspection
  • We summarize the results in a detailed report, including a risk value for each machine

Your advantage

  • The "status check" identifies hazards for employees as well as deviations with respect to legal requirements
  • The results provide recommendations for a fast reaction in the event of acute hazards
  • The risk value for each machine simplifies the prioritization of necessary corrective measures

 


 

Hazard assessment

Your requirement

The Betriebssicherheitsverordnung (Ordinance on Industrial Safety and Health, BetrSichV) includes the legal requirement for employers that a hazard assessment be conducted before work equipment is used and that this be updated at regular intervals according to the current state of the art. This ensures that the machine is safe for the machine operator over its entire lifetime since modifications, extensions or wear change the state of the machines and of the used protective devices over time.

 

Our solution

  • Analysis of the existing mechanical dangers
  • Estimation of the existing dangers and calculation of a risk indicator
  • Report with description of the need for action

Your advantage

  • Secure legal basis for the operation of the machine
  • Guarantee of a safe work environment
  • Independent, external assessment