Overarching safety control system for a production line

Context:
When several standard machines were assembled into a single production line for cutting and packaging cheese, the risk study under Machinery Directive 2006/42/EC revealed that the individual machines offered insufficient integration options to achieve a safe line. An overarching safety control system was needed to guarantee safety across the entire line.

Approach:
Prohead Engineering designed and implemented a separate safety control system that acts as master, with the safety controllers of the individual machines connected as slaves.

• The intended safety matrix was realised using a safety PLC.
• Loose and mobile conveyors were also integrated into the control system. For these mobile conveyors, each fitted with an emergency stop, an illuminated emergency stop was provided. In accordance with EN ISO 13850, it is therefore always clear whether the emergency stop is active: the red-yellow colour only appears when the conveyor is actually connected.
• Thanks to the overarching control system, the necessary interfaces with adjacent machines could also be realised without major modifications to the standard machines.

Result:
The production line was demonstrably brought into conformity with the Machinery Directive without the need for major changes to the individual machines. By guiding the process from study to solution, Prohead Engineering ensured a safe, flexible and future-proof integration of the line.