FINAL DOCUMENT AFTER WG3 MEETING ON 3-4 … · EN ISO 14122-3: 2016 - Safety of machinery — Permanent means of access to machines and industrial plants — Part 3: Stairways, stepladders

1

CEN TC 146

Date: 2017-07

PrEN415-4

CEN TC 146/WG3- 28

Secretariat: UNI

Safety of packaging machines - Part 4: palletizers and depalletizers and

associated equipment

Sécurité des machines d'emballage

Partie 4 : Pallettiseurs et dépalettiseurs et èquipement associè

Sicherheit von Verpackungsmaschinen –

Teil 4: Palettierer und Depalettierer und zugehörige Ausrüstungen

ICS:

Descriptors:

FINAL DOCUMENT

AFTER WG3 MEETING ON 3-4 July 2017

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Contents

Foreword

Introduction

1. Scope

2. Normative references

3. Terms and definition

4. Hazards on palletizers and depalletizers

5. Safety requirements and/or protective measures for palletizers ,

depalletizers and associated equipment

6. Verification of safety requirements and measures

7. information

3

Foreword

This document (PrEN 415-4: 2017) has been prepared by Technical Committee CEN/TC 146, "Packaging machines - Safety", the secretariat of which is held by UNI.

This document is a revision of EN 415-4:1997 according to Machine Directive 2006/42/CE.

This document has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association and supports essential requirements of EU Directives.

For the relationship with EU Directives, see informative Annex ZB, which is an integral part of this document.

Other standards produced by this Technical Committee are:

EN 415 Safety of packaging machines;

Part 1: Terminology and classification of packaging machines and associated equipment.

Part 2: Pre-formed rigid container packaging machines.

Part 3: Form, fill and seal machines.

Part 5: Wrapping machines.

Part 6: Pallet wrapping machines.

Part 7: Group and secondary packaging machines

Part 8: Strapping machine

Part 9: Noise measurement methods

Part 10: General requirements

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Introduction

This document is a C standard as defined in the introduction of ISO EN 12100: 2010

The machinery concerned and the extent to which hazards, hazardous situations and events are covered are indicated in the scope of this European Standard.

When provisions of this type C standard are different from those that are stated in type A or B standards, the provisions of this type C standard take precedence.

1. Scope

This European Standard applies to the following groups of machines, auxiliary equipment and their combinations: - Palletizers - Depalletizers - Auxiliary equipment - Conveying system which are part of palletizers or depalletizers The individual machines are described in clause 3.3.

For all packaging machines within the scope of this standard EN 415-10 applies too. En 415-4 standard describes the additional or specific hazards for palletizers and depalletizers. The requirements of this standard will take precedence over the requirements set out in EN 415-10.

This European Standard deals with safety requirements for machine design, transport, installation, commissioning, operation, adjustment, maintenance and cleaning of palletizers, depalletizers, auxiliary equipment and conveying systems which are part of palletizer or depalletizer. The extent to which hazards, hazardous situations and events are covered, are indicated in clause 4.

Note: The hazards on a specific machine can vary depending on its working principle, the type, size and mass of the product, the packaging material, auxiliary equipment attached to the machine and the environment in which the machine is used. If the machine presents hazards that are not covered by this standard or EN 415-10, the manufacturer should assess these hazards and take measures by using the principles detailed in EN ISO 12100.

Exclusions:

This standard is not applicable to the following machines:

Machines where the layer is built manually on the pallet or pallet load without layer forming and layer transfer

Machines that were manufactured before the date of publication of this document by CEN; Conveying systems that connect palletizers or depalletizers with others machines but includes

conveyors that are part of the machines to the extent that they could reduce the effect of the protective devices of the palletizer or depalletizer. When provisions of EN 619 (Continuous handling equipment and systems) are different from those that are stated in this standard, the provisions of EN 415-4 take precedence.

This standard does not consider the following hazards:

the intended use of palletizers and depalletizers in potentially explosive atmospheres;

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the health, safety or hygiene hazards associated with the products that are contained in the unit load handled by palletizers and depalletizers except with regard to possible malfunction of a machine causing spillage of hazardous substances.

2. Normative references

The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 415-1:2011 - Safety of packaging machines — Part 1: Terminology and classification for packaging

machines and associated equipment

EN 415-9:2009 -Safety of packaging machines — Part 9: Noise measurement methods for packaging

machines, packaging lines and associated equipment, grade of accuracy 2 and 3

EN 415-10:2014 -, Safety of packaging machines – General requirements

EN 619:2002 + A1:2010 -, Continuous handling equipment and systems — Safety and EMC requirements

for equipment for mechanical handling of unit loads

EN 1005-3:2002 + A1:2008 -, Safety of machinery — Human physical performance — Part 3:

Recommended force limits for machinery operation

IEC 60204-1: 2016 – Safety of machinery – Electrical equipment of machines – part 1: General requirements

EN 61496-1:2013 - Safety of machinery — Electro-sensitive protective equipment — Part 1: General

requirements and testing

IEC 61496-2:2013 -, Safety of machinery — Electro-sensitive protective equipment — Part 2: Particular

requirements for equipment using active opto-electronic Protective Devices (ESPEs)

IEC 61496-3:2008 --, Safety of machinery — Electro-sensitive protective equipment — Part 3: Particular

requirements for active opto-electronic Protective Devices responsive to Diffuse Reflection (ESPEDR)

EN 62061:2005+ A2 2015, Safety of machinery — Functional safety of safety-related electrical,

electronic and programmable electronic control systems

EN ISO 10218-1: 2011- Robot and robotics devices – safety requirement for industrial robot – part 1

Robots

EN ISO 10218-2: 2011 -, Robot and robotics devices – safety requirement for industrial robot – part 2

Robot system and integration EN ISO 11161: 2007 + A1: 2010 -, Safety of machinery – Integrated manufacturing systems – Basic

requirements

EN ISO 12100:2010 -, Safety of machinery –General principles for design – Risk assessment and risk

reduction

EN ISO 13849-1:2015 -, Safety of machinery — Safety related parts of control systems — Part 1: General

principles for design

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EN ISO 13855: 2010 - Safety of machinery — positioning of protective equipment with respect to the

approach speeds of parts of the human body

EN ISO 13857:2008 - Safety of machinery — safety distances to prevent danger zones being reached by

upper and lower limbs

EN ISO 14122-2: 2016- Safety of machinery — Permanent means of access to machines and industrial

plants — Part 2: Working platforms and walkways

EN ISO 14122-3: 2016 - Safety of machinery — Permanent means of access to machines and industrial

plants — Part 3: Stairways, stepladders and guard-rails

3. Terms and Definitions

3.1 General

For the purposes of this standard, the definitions given in Clause 3 of EN ISO 12100:2010, EN 415-1:2014, EN 415-10: 2014 and the following shall apply:

3.2 Definitions

3.2.1 To palletize: operation of placing one or more unit loads on a pallet or similar support.

3.2.2 To depalletize: the separation of a palletised load into individual unit loads.

3.2.3 Layer: arrangement of unit loads in a horizontal plane.

3.2.4 Layer sheet: (layer pad or intermediate layer) sheet of material placed between layers to stabilize a pallet load.

3.2.5 Layer pattern: disposition of the unit load in a layer.

3.2.6 Pallet: rigid horizontal platform designed to be handled by pallet trucks, fork-lift trucks or other appropriate handling equipment, and used as a base for assembling, loading, storing, handling, stacking, transporting, or displaying goods and loads. Note to entry: The pallet may be constructed with, or fitted with, a superstructure.

3.2.7 Pallet load: arrangement of unit loads placed on a pallet or slip sheet.

3.2.8 Porous vacuum plate: plate made of porous material which holds a product by means of a vacuum

3.2.9 Row: horizontal line of unit loads.

3.2.10 Slip sheet: thin flat piece of material to support a pallet load.

3.2.11 Stack: vertical column of unit loads

3.2.12 Integrator: entity who designs, provides, manufactures or assembles an integrated manufacturing system and is in charge of the safety strategy, including the protective measures, control interfaces and interconnections of the control system note: the integrator may be a manufacturer, engineering company or the user

3.2.13 Integrated palletizing system: group of machines working together in a coordinated manner, linked by material handling system, interconnected by controls for the purpose of palletize or

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depalletize pallets. 3.3. Description of palletizers and depalletizers

3.3.1 General

This clause describes the working principles of typical assemblies of palletizers and depalletizers. Variations of these typical assemblies also exist.

3.3.2 Semiautomatic stripper plate palletizer

An operator groups unit loads on a stripper plate forming the desired layer pattern then activates the machines which transfer the layer to the pallet. The stripper plate retracts, deposits the layer on the pallet and then returns to the layer forming position. Pallets are handled manually or by truck or transported by conveyor.

3.3.3 Automatic low level palletizer or depalletizer

Layers of packages are formed at one level, usually at low level, transferred by pushing onto a stripper plate which raises or lowers to the appropriate level and transfers the layers onto the pallet. The pallet remains at one level while being formed. For depalletizers layers of packages are gripped and swept onto a stripper plate which moves to the level of a receiving table where the layer is deposited. The pallet remains in a fixed position while it is being dismantled.

3.3.4 Automatic high level palletizer or depalletizer:

Layers of packages are formed at one level usually a high level, and transferred onto the pallet which is raised and then lowered as the pallet forms. A depalletizer operates in reverse: layers of packages are gripped and moved from a pallet onto a receiving table, usually positioned at high level. The height of the pallet is raised as the pallet is dismantled.

3.3.5 Pick and place palletizer or depalletizer

Palletizer in which products are gripped, lifted, transferred to the loading position and then lowered onto the pallet load with linear movements and a rotation of the end effector. Note to entry: the pallet/load remains at one level while it is being loaded 3.3.6 Column pick and place palletizer or depalletizer:

Pick-and-place palletizer in which the product lifting device is supported on a column and can move up and down the column or rotate around the column. A rotation of the end effector may also exixt.

Note to entry: column palletizers can pick up packages one at a time, or a row at a time, or a layer at a time. Unit loads are generally conveyed to the machine at low level but certain designs have an input of unit loads at high level. Typical there is a spacing conveyor, an orientation device and a raw or layer preparation table for unit loads. The column palletizer is suitable for systems where more than one pallet is loaded from one or more sources. Pallets are transported through the machine by a conveyor. The machine may combine the loading and unloading in a single compact installation.

3.3.7 Stack palletizer:

Palletizer which creates stacks of packages e.g. crates which are then transferred to the pallet as a group.

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3.3.8 Robot palletizer and depalletizer:

Pallettizer or depalletizer which uses a multi-axis industrial robot to perform some or all the functions. Robot palletizer can pick up product one in a time , a row at a time or a layer at a time. In some installations the robot also positions the pallet or the layer sheets. 3.3.9 Case-packer-palletizer:

A machine which combines the operations of case-packing and palletizing using a single robot.

3.3.10 Multi-station palletizing system

Palletizer in which two or more pallet loads of products are formed in the same machine.

Note: The pallet loads are usually loaded and/or unloaded by an industrial truck, e.g. AGV or fork lift truck.

3.4 Description of auxiliary equipment

3.4.1 General

This clause describes the working principle of typical auxiliary equipment used in palletizers and depalletizers.

3.4.2 Mechanical gripper

These have mechanical elements which support or clamp the unit load, set of products, empty pallet or interlayer. The clamping action may employ the following methods:

a) positive action

b) friction between the fingers or plates and the loads c) friction between the loads d) pressure by an inflatable element.

3.4.3 Vacuum gripping head

Product is lifted by several suction cups or by a porous vacuum plate which applies a vacuum to the surface of the product.

3.4.4 Magnetic gripping head

Products made of ferromagnetic material are lift by means of electromagnetic force.

3.4.5 Gripping head with roller curtain

Product is transferred onto a roller curtain which is then lifted and conveyed onto a pallet. The roller curtain is then retracted leaving the product on the pallet.

3.4.6 Pallets magazine

The machine dispenses empty pallets from a stack or accepts single empty pallets and places them in a stack.

3.4.7 Pallet changer

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The machine removes a pallet load from a pallet so that it can be placed on another pallet.

3.4.8 Pallets grouping and ungrouping units

Pallets are fed by a fork lift truck onto a roller conveyor which stores, sorts and delivers the pallets to various loading stations. Pallets may turn and move in all directions. The system may handle empty or full pallets. A system for the control of the quality of pallets and the sorting of damaged pallets may be present.

3.4.9 Device for insertion or removal of layer sheets

This is typical auxiliary equipment which can be incorporated into several different palletizers or depalletizers. A device inserts layer sheets into, or removes layer sheets from a magazine which is situated inside the interior zone at the position where the layers are removed or deposited (figure 16a) The stack of layer sheets is normally fed or removed manually by an operator standing outside the interior zone. However, the insertion or removal of layer sheet can be performed by a robotized system as shown in Figure 16b. The layer sheet is removed in the inside zone and deposited in the operative zone through a narrow slot. A similar system can also move empty pallets.

3.4.10 Pallet checkers

3.4.10.1 Pallet size/weight checker

This equipment may consist of a roller conveyor with load cells for weighing pallets, or another control station, usually equipped with photoelectric equipment, to check the size of the palletized load. Note to entry: This equipment is often combined with a labelling machine or devices for the selection and sorting of the pallets. It is normally part of a palletizing system.

3.4.10.2 Pallet condition checker This equipment checks various attributes of the pallet, e.g. presence of boards, free space or stringers in bad condition. If a pallet does not meet the quality requirements, it is rejected. 3.5 Definition of zones The zones of a palletizer or depalletizer (which are classified in figure 1 but may differ in the real situations and defined in the instruction manual) and the inside zone shall be made evident with warning signals placed on the machine.

For each zone the manufacturer shall identify the intended operations which can be performed and the safety procedures to be used. For the description of the safety measures it is useful to define the relevant zone of typical palletizer or depalletizer which, in general, are: 1) Open space (circulation zone): is the space around the palletizers where the operators may be present, even not very often. 2) Operative zone (working zone): is the space where the operators are normally present and where

the “operator position” is. 3) Part of the inside zone where operators, under special condition, may be present 4) Inside zone (interior zone): is the space where the machine operates and where the major risks are

present and the operators are outside. This zone may be divided in 2 or more inside sub-zones in order to establish requirement for safe access in a sub-zone while the others are in operation. Inside zone is also called “hazard zone”

5) Infeed zone: is the space where the products enter in the inside zone. May be more than one. 6) Outfeed zone: is the space where the products exit the inside zone. May be more than one.

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Figure 1 – Typical zones of palletizers

4. Hazards on palletizers, depalletizers and auxiliary equipment

4.1 General

This clause lists all the significant hazards together with hazardous situations and events which occur on palletizers, depalletizers, and auxiliary equipment described in clause 3. It therefore covers all palletizers, depalletizers, as well as auxiliary equipment and conveyors that form part of the machines covered in this standard.

In addition, hazards that are specific to the machines in Clauses 4.2 to Clause 4.18, are listed in these clauses

The relevant phases of the machine life cycle, hazardous situations and events considered are: phases of the machine life cycle:

o installation, assembly, dismantling o operation (e.g. automatic mode, manual feeding, process intervention) o changeover o fault finding, trouble-shooting, setting, adjustment o cleaning o maintenance

hazardous situations, events:

o unintended contact o exposure o staying in the vicinity o machine in operation o unexpected start-up o malfunction o work underneath a load

Particular situations are described within the tables for specific machines. When a palletizer or depalletizer incorporates auxiliary equipment the specific hazards of the auxiliary equipment shall be taken into account.

4 4

3

1 2

3

4 4 5 6

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Table 1- Significant hazards which are common for all palletizers and depalletizer, auxiliary

equipment and conveying systems which are part of palletizers or depalletizers.

Source of hazards,

hazardous elements

Hazards, phases of life cycle, hazardous

situations / events

Reference to

safety

requirement of

this standard

Mechanical hazards moving machine or moving parts of the machine, cutting equipment, handles or hand wheels loss of stability of the machine or machine parts

Mechanical hazards according to 4.2, 4.16.5 or 4.16.6 of 415-10:2014

5.1.2 5.1.4 5.1.5

moving, falling, ejected product

Mechanical hazards according to 4.2, 4.9.1 d) and 4.9.2 c) of 415-10:2014

5.1.13 - 5.1.24 5.1.27

broken or damaged product, packaging material

cutting or stabbing e.g. according to 4.9 of 415-10:2014

5.1.13

Pneumatic equipment or hydraulic equipment

Mechanical hazards, ejections of air, whiplash of pipes and slipping or falling, noise according to 4.3 of 415-10:2014

5.1.8

loss of stability of the machine or machine parts

Mechanical hazards according to 4.2.3 of 415-10: 2014

5.1.7

Pallet conveyors hazards according to 4.16.4 of EN 415-10:2014

5.1.12

Electrical hazards electrical equipment, conductive parts of the machine

Electric shock according to 4.4 of 415-10:2014

5.1.10

Noise machine, parts of the machine, product, equipment associated to the machine

noise according to 4.7 of 415-10:2014 5.1.11

Radiation hazards equipment for coding or checking product or packages using radiation

radiation hazards according to 4.8 of EN 415-10:2014

5.1.30

Chemical hazards emission of harmful substances

hazards to health, chemical burn e.g. according to 4.9, 4.16.2, 4.16.7 of EN 415-10: 2014

5.1.31

Fire explosion hazards product, substances used with the machine

fire, explosion, e.g. according to 4.9, 4.16.2, 4.16.7 or 4.16.8 of EN 415-10:2014

5.1.31

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4.2 Semiautomatic stripper plate palletizer

Figure 2 shows an example of semiautomatic stripper plate. The significant hazards on this machine are listed in table 2

Figure 2 Example of Semi-automatic stripper plate palletizer

Table 2 – Significant hazards and hazardous situations on semiautomatic stripper plate

palletizer

Ha

za

rd Z

on

e Source of

hazards

Hazards Hazardous situation -

phase of life cycle

Reference to

safety

requirement

of this

standard

1 mass of product Crushing, impact ergonomic hazard

Phase of life cycle: - operation

Situations:

- manual feeding, falling product while lifted

- falling product while stripped and persons (e.g. operator of fork lift truck) in the vicinity

5.2.1

2 interface between conveyor and grouping table

drawing-in Phase of life cycle: operation

5.2.2

3 - 4 moving stripper plate, moving cross bar

crushing, shearing impact

Phase of life cycle: - operation

Situations: unexpected start up person, e.g. operator of the machine or operator of fork

5.2.2 5.2.3

1

2

3

5

4

13

4.3 Automatic low level palletizer or depalletizer

Figure 3 shows an example of low level palletizer or depalletizer. The significant hazards on this machine are listed in table 3.

Figure 3 – Example of automatic low level palletizer

Table 3: significant hazards and hazardous situations on on automatic low level palletizer

Ha

za

rd z

on

e Source of hazards Hazards Hazardous situation -

phase of life cycle

Reference to

safety

requirement

of this

standard

lift truck) in hazard zone e.g. because of carelessness

5 lifting mechanism crushing, shearing, impact

Phase of life cycle: operation Situations: unexpected start up lowering of lifting mechanism while standing underneath (operation, maintenance, cleaning, driven or unexpected, e.g. by gravity

5.2.1 5.2.2 5.2.3

1

2

14

1 Load lifting device Mechanical hazards Phases of life cycle: - Operation

Situations: -unexpected start up - movement of load

lifting devices in all phases e.g. lowering by gravity

5.3.1 5.3.2 5.3.4

2 Mass of unit load Mechanical hazards Phases of life cycle: - operation - maintenance - cleaning - setting - removal of jam

Situations: - falling of load

5.3.1 5.3.2 5.3.3

4.4 High level palletizer and depalletizers

Figure 4 shows an example of high level palletizer and depalletizer. The significant hazards on this machine are listed in table 4.

Figure 4- Example of high level palletizer

Table 4- Significant hazards and hazardous situations on for high level palletizer and

depalletizer

1

2

3

4

5

7

6

15

Ha

za

rd Z

on

e Source of hazards Hazards Hazardous

situation /

phase of life

cycle

Reference to

safety

requirement

of this

standard

1 Belt conveyor Mechanical hazards/ friction/ drawing in/ falling products/ persons

Phase of life cycle:

- operation - changeover - fault finding - cleaning

maintenance Situation: unexpected start up access during operation

5.4.1 5.4.2 5.4.3

2 Turning device Mechanical hazards/ drawing in/ crushing/ falling products/ persons

Phases of life cycle:


maintenance - setting - removal of jam

- Situation: - access during

operation falling of load

5.4.1 5.4.2 5.4.3

3 Layer forming Mechanical hazards/ drawing in/ crushing/ shearing/ falling products/ persons



maintenance Situation: access during operation

5.4.1 5.4.2 5.4.3

4 High level access point

Tripping, slipping, falling Phases of life cycle:


maintenance Situation: access to high points

5.4.1

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5 Mass of pallet in the stack

Mechanical hazards/ crushing / shearing



maintenance Situation: access during operation

5.3.1 5.3.2 5.3.3 5.3.4

7 Pallet load lifting device

Mechanical hazards/ crushing



maintenance Situation: access during operation movement of load lifting devices in all phases e.g lowering by gravity

5.3.2 5.3.3 5.3.4

4.5 Pick and place palletizer and depalletizer and colunm pick and place palletizer or

depalletizer

Figure 5a shows an example of pick and place palletizer or depalletizers; figure 5b shows an example of column palletizer or depalletizers,. The significant hazards on these machines are listed in table 5

1 2

17

Figure 5a- Example of automatic pick and place palletizer or depalletizer

Figure 5 b - Example of colunm pick and place palletizer or depalletizer

Table 5 - Significant hazards on automatic pick and place palletizer or depalletizer and column

pick and place palletizer or depalletizer

Ha

za

rd

Zo

ne

Source of hazards Hazards Hazardous situation /

phase of life cycle

Reference to

safety

requirement

of this

standard

1 Product lifting and moving device

Mechanical hazards Phases of life cycle: - operation - changeover - fault finding - cleaning - maintenance Situations: - Unexpected start up - movement in all

directions of lifting device while person is present

- unexpected lowering

5.5.2 5.5.3 5.5.4

2 Operator standing at high level

Crushing, impact Phases of life cycle : - operation - changeover - fault finding - cleaning - maintenance

Situation: - falling from high level

5.5.1

1

2

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4.6 Robot palletizer or depalletizer

Figure 6 shows an example of robot palletizer and depalletizer. The significant hazards on this machine are listed in table 6.

Figure 6 - Example of robot palletizer

Table 6 - Significant hazards and hazardous situations on robot palletizer or depalletizer

Ha

za

rd z

on

e Source of hazards Hazards Hazardous situation

/ phase of life cycle

Reference to

safety

requirement

of this

standard

1 Moving parts Mechanical hazards Phases of life cycle: - operation - changeover - fault finding - cleaning - maintenance

Situations: - failure of control

system if a person is in the vicinity

- operator trapped inside the hazard zone,

- unexpected start up, - lack of visibility

from the operator panel

5.6.1 5.6.2 5.6.3 5.6.4

3 4

1

19

2 Ejecting of products, pallets, or packaging components (e.g. layer sheet,)

Impact, crushing Phases of life cycle: - operation - changeover - fault finding - cleaning - maintenance Situations: - failure of a gripping

system when an operator is standing below

5.6.2

3 Conveyor Slip, falling, impact Phases of life cycle: - operation - changeover - fault finding - cleaning

maintenance

Situations: - operator standing

on roller conveyor - Unexpected start-up

5.4.1

4 Access from high level Access from high level Slip, trip and fall hazards according to 4.2.2 of 415-10:2014

5.4.1

4.7 - Case packer palletizer

Figure 7 shows an example of case packer palletizer. The significant hazards on this machine are listed in table 7.

Figure 7 - Example of case packer palletizer

Table 7 - Significant hazards and hazardous situations on on case packer palletizer

1

20

4.8 - Multi stations palletizing system

Figure 8 shows an example of multi station palletizing system. The significant hazards on this machine are listed in table 8.

Figure 8 - Example of Multi stations palletizing system

Table 8 - Significant hazards and hazardous situations on multi stations palletizing system

Ha

za

rd

Zo

ne

Source of hazards Hazards Hazardous situation


Reference to safety

requirement of this

standard

1 Moving parts Mechanical hazards Phases of life cycle: - Operation

Situations: - unexpected

movement of robot - unexpected start up

of gripper - e.g. outside the

prescribed area

5.7

Note: for the machine section “case packer” reference can be done to list of hazard and safety requirements of EN 415-7

4 2

1 - 3

5 6

21

Ha

za

rd Z

on

e Source of hazards Hazards Hazardous situation /

phase of life cycle

Reference

to safety

requireme

nt of this

standard

1 Moving parts of the palletizer

Mechanical hazards Phases of life cycle : - operation - changeover - fault finding - cleaning - maintenance

Situations: - unexpected start up e.g when people is in the hazard - area,manual start after manual operations on the machine,

- lack of visibility of all zones while starting the machine,

- automatic start after switching off the access control systems.

- defeating of safety measures due to cumbersome control measure in the access zone

5.8.1 5.8.2

2 Moving parts of the palletizer

Mechanical hazards Phases of life cycle - operation

Situations: - access during pallet change (by fork lift trucks or by AGV) failure of safety related control system including software

5.8.1

5.8.2

3 Moving part and product

Mechanical hazards Phases of life cycle - operation

Situations - conveyors moving to

buffer products while the other moving parts of the machine are still

5.8.1

5.8.2

22

4.9 – Mechanical Gripper

Figure 9 shows examples of mechanical grippers. The significant hazards on these equipment are listed in table 9.

4 Dropping of products, pallets, or packaging components (e.g. layer sheet,)

Impact, crushing Phases of life cycle - operation - changeover - fault finding - cleaning - maintenance

Situations - failure of a gripping


5.5.2

5 Ejecting of products, pallets, or packaging components (e.g. layer sheet,)

Impact, crushing Phases of life cycle: - operation - changeover - fault finding - cleaning - maintenance Situations: - failure of a gripping


5.5.2 5.6.3

Note: Lack of coordination between the manufacturers involved in the multi-station palletizing system may create hazards. Annex C (informative) includes information on the flow of information between integrator, user and manufacturers and any other suppliers in order to minimize the risk.

1 2-3

Figure 9 a Figure 9 b

2

23

Figure 9 c

Figure 9 - Example of mechanical grippers

Figure 9 a) examples of mechanical gripper (form fit)

Figure 9 b) examples of pneumatic gripping fingers (force fit)

Figure 9 c) examples of gripping head with inflatable elements (force fit)

Table 9 - Significant hazards and hazardous situations on gripping heads

Ha

za

rd Z

on



Reference to

safety

requirement

of this

standard

1 Falling product Impact, mechanical hazards Phases of life cycle: - operation - changeover - fault finding - cleaning - maintenance

Situations: - Unexpected start up - falling of load while

operator standing below or in the proximity

5.9.1

2 Moving parts Mechanical hazards Phases of life cycle: - changeover - fault finding - cleaning

Situations: - unexpected start up

maintenance, setting or removal of jam due to failure of safety related part of control system

5.9.1

24

4.10 – Vacuum gripping head

Figure 10 shows an example of gripping head with vacuum. The significant hazards on this equipment are listed in table 10.

Figure 10 - Example of gripping head with vacuum

Table 10 - Significant hazards and hazardous situations on gripping heads with vacuum

Ha

za

rd Z

on

e Source of hazards Hazards Hazardous

situation / phase of

life cycle

Reference to

safety

requirement

of this

standard

1 Falling of product Impact, crushing Phases of life cycle: - operation - changeover - fault finding - cleaning - maintenance

Situations: - poor adhesion

between suction cups and product to be lifted or failure of power supply and lack of vacuum

5.10.1 5.10.2

4.11 - Magnetic gripping head

Figure 11 shows an example of magnetic gripping head. The hazards on this equipment are listed in table 11

1

25

Figure 11 - Example of magnetic gripping head

Table 11 - Significant hazards and hazardous situations on magnetic gripping head

Ha

za

rd Z

on

e Source of hazards Hazards Hazardous situation phase

of life cycle

Reference to

safety

requirement

of this

standard

1 Falling of product Impact, crushing Phases of life cycle: - operation - changeover - fault finding - maintenance

Situations: - Unexpected start up - failure of energy supply or

failure of the control system

5.11.1

2 Electromagnetic field radiation Phases of life cycle: - operations Situations:

- person wearing implanted medical devices in the vicinity

5.11.1

4.12 - Gripping head with roller curtain

Figure 12 shows an example of gripping head with roller curtain. The significant hazards on this equipment are listed in table 12

1

2

26

Figure 12 - Example of gripping head with roller curtain

Table 12 - Significant hazards and hazardous situations on gripping head with roller curtain

Ha

za

rd Z

on



Reference to

safety

requirement

of this

standard

1 Falling of product Impact crushing Phases of life cycle - operation - changeover - fault finding - cleaning - maintenance Situations - Unexpected

movement due to failure of control system

5.12.1

1

1

2

27

2 Moving parts Mechanical hazards Phases of life cycle: - changeover - fault finding - cleaning

Situations: - unexpected start up

maintenance, setting or removal of jam due to failure of safety related part of control system

5.12.1

4.13 - Pallet magazine

Figure 13 shows an example of pallet magazine. The significant hazards on this equipment are listed in table 13

Figure 13a Examples of pallet magazine

1

2

3

28

Figure 13 b - Examples of pallet of magazine

Table 13- Significant hazards and hazardous situations on pallet magazine

Ha

za

rd z

on


phase of life cycle

Reference to

safety

requirement

of this

standard

1 Mass of pallet Impact, crushing Phases of life cycle: - operations

Situation: - person in the vicinity - Falling of pallet from

high level - Tilting of the pallet

stack

5.13.1

2 Pallet load lifting device

Impact and crushing Crushing between pallet and frame of machine

Phases of life cycle: - Operations - fault finding - trouble-shooting, setting, adjustment cleaning, maintenance Situation: - person in the vicinity

Driven movement or unexpected lowering of pallet load lifting device”

Failure of safety related part of control system

5.13.2 5.13.3

1

2

3

29

3 Moving parts Impact, crushing Phases of life cycle: - operations - changeover - fault finding - cleaning

Situations: - Instability and due to

damaged pallet - Unexpected start up

5.13.2

4.14 - Pallet changer

Figure 14 shows an example of pallet changer. The significant hazards on this equipment are listed in table 14

Figure 14 - Example of pallet changer

Table 14 - Significant hazards and hazardous situations on pallet changer

Haz

ard

Zone

Source of hazards Hazards Hazardous situation / phase of life cycle

Reference to

safety

requirement

of this

standard

1 Falling of product Impact Phases of life cycle: - operations

Situations: - person in the vicinity

5.14.1

1 - 2

30

2 Movement of pallet and sheet, movement of machine parts

Impact, crushing Phases of life cycle: - operations

Situations: - person in the vicinity - failure of part of control

system - failure of electronic drive

system

5.14.1 5.14.2 5.14.3

4.15 - Grouping and ungrouping unit

Figure 15 shows an example of grouping and ungrouping unit. The significant hazards on this equipment are listed in table 15

Figure 15 - Example of pallet grouping and ungrouping unit

Table 15 - Significant hazards and hazardous situations on pallet grouping and ungrouping unit

Haz

ard

Zone

Source of hazards Hazards Hazardous situation / phase of life cycle

Reference to

safety

requirement

of this

standard

31

1 Moving parts Drawing-in, entanglement, impact

Phases of life cycle: - operations

- changeover - fault finding - -cleaning Situations:

- Unexpected start up - Feeding of conveyor by an operator

5.15.1

2 Movement of pallet Impact, crushing with pallets

Phases of life cycle: - operations

Situations: - Unexpected start up

- person in the vicinity

- failure of safety related part of control system during normal operation

5.15.1

4.16 - Device for loading or unloading of layer pads

Figure 16 shows an example of a device for the removal of layer sheet. The significant hazards on this equipment are listed in table 16

a) palletizer with device for manual loading or unloading b) automatic system

2

Picking and handling of layer pad

Handling and releasing of layer pad

1

Inside zone operative zone

32

Figure 16 Example of device for the unloading of layer sheets

Table 16 - Significant hazards and hazardous situations on device for the removal of layer sheet

Ha

za

rd

Zo

ne

Source of hazards Hazards Hazardous situation /

phase of life cycle

Reference to

safety

requirement

of this

standard

1 Automatic handler of layer sheet

Mechanical hazards Phases of life cycle: - Operations

Situations: - Unexpected start up - person in the hazard

zone - Manual insertion or

removal of layer sheets

5.16.1

2 Movement of part of the machine

Mechanical hazards Phases of life cycle: - operations Situations: - Unexpected start up

person in the hazard zone -Failure of safety related part of control system -Failure of electronic drive system

5.16.2 5.16.3

4.17 Pallet size/weight checker

Figure 17 shows an example of pallet size/weight checker. The significant hazards on this equipment are listed in table 17

Figure 17- Example of pallet size/weight checker

1

2

33

Table 17 - Significant hazards o and hazardous situations on pallet size/weight checker H

az

ard

Zo

ne

Source of hazards Hazards Hazardous situation


Reference to

safety

requirement

of this

standard

1 Pallet and load moving along the conveyor crossing the supporting beams

Mechanical hazards Phase of life cycle: Normal operation

Situations: Unexpected start up

5.17.1

2 Movement of pallet Impact, crushing Phase of life cycle: - operation

Situations: - person in the hazard zone

5.17.1

4.18 Pallet condition checker

Figure 18 shows an example of pallet condition checker. The hazards on this equipment are listed in table 18

Figure 18 – Example of pallet condition cheker

Table 18 – Significant hazards and hazardous situations on pallet condition checker

1

2

34

Ha

za

rd Z

on


phase of life cycle

Reference to

safety

requirement

of this

standard

1 Movement of pallet Impact, crushing Phase of life cycle: - operation

Situations: - person in the hazard zone

5.18.2

2 Movement of part of the machine

Mechanical hazards Phases of life cycle: - operations

Situations: - person in the hazard

zone

5.18.1 5.18.2

5. Safety requirements and/or protective measures for palletizers

depalletizers and associated equipment

5.1 General requirements

5.1.1 General

All machines in the scope of the standard shall comply with the following requirements.

For relevant hazards which are not listed as significant in this standard, EN 415-10 applies.

5.1.2 Inherently safe design – physical aspects

The requirements of EN 415-10: 2014 clause 5.2.1.1 shall apply. Note: annex B (informative) of EN 415-10: 2014 provide maximum values for inherently safe design.

5.1.3 Prevention of break-up during operation by design

5.1.3.1 Strength of mechanical elements

Mechanical elements which support a load shall be designed and constructed in such a way as to withstand the static overload without permanent deformation or patent defect. A static test coefficient 1,5 applies.

In addition the following elements which support a load shall have the working coefficients as listed below when using only 1 element: • rope 5 • chain 4 • belt 5 • textile fibre 7 • toothed belt 5

35

Other mechanical parts of lifting mechanism shall be calculated according to good engineering practices. EN 13001-1 and EN 13001-2 provide useful information.

NOTE: the manufacturer of these elements may certify the “load limit” which incorporate the safety coefficient. The “load limit” can be used as reference data for the design of the elements of the power transmission. Preferably more than one chain, rope or fiber should be used.

Using 2 or more elements the minimum factor of each element shall be not less than the factors stated above divided by the number of elements but at least the factor shall be 2.

5.1.3.2 Measures for ropes or similar devices, hydraulic or pneumatic equipment to prevent

unintended lowering of lifting units

To prevent the unintended lowering of lifting units of the following measures shall be applied:

a) Mechanisms using chains, ropes, belts or fibres shall have a slack rope detection which leads to a cessation of movement when initiated.

b) As an alternative an automatic tensioning device which keeps the contact between belt and cog pulley.

c) As alternative a counter roll which prevents the belt or chain to lose the connection with the cog pulley.

d) If hydraulic cylinders are used they shall be equipped with an automatic device to limit unintentional lowering to less than 100 mm even in the event of rupture of the hoses in the hydraulic supply line. The device shall be effective even in case of failure of the power supply.

e) If pneumatic cylinders are used, they shall be equipped with a rod blocking device or a pressure relief valve effective even in case of failure of the power supply.

The manufacturer shall describe the safe procedures and measures following a breakdown of the above elements or a response of the above safety devices. This shall include how to move the lifting mechanism to a safe position, prevention of any hazardous movement of lifting units, safe access and safe removal of load as well as the necessary maintenance actions. 5.1.4 Fixed or interlocked movable guards

The requirements of EN 415-10:2014 clause 5.2.1.2 shall apply. For access with lower limbs reference to EN 13857 annex B shall be done. 5.1.5 Apertures in guards

Clauses from 5.2.1.3 to 5.2.1.4 of EN 415-10: 2014 and in addition 5.1.5.2 to 5.1.5.3 shall apply .

5.1.5.2 Access over belt or apron belt conveyors

Where a conveyor with even plane such as a belt or apron belt conveyor is used, the maximum clearance between the pallet load and the columns of ESPE or guards shall be 180 mm to prevent operator from passing through the gap during muting.

5.1.5.3 Minimum distance for belt or chain or roller conveyors For calculation of the minimum distance of an AOPD or AOPDDR for access over a conveyor the approach speed K according to EN 13855 for walking may be reduced to 800 mm/s when all of the following conditions are fulfilled: For chain conveyors or a belt conveyors:

36

- the minimum distance between the center of the chains or belts is 550 mm and - the belts or chains are not wider than 100 mm and - measures are taken between the chains or belts to slow down the approach speed, e.g. obstacles like nets For roller conveyors: - the minimum clearance between rolls is 120 mm and - the side bars are not wider than 40 mm.

5.1.5.4 Alternative measures for large apertures When muting of ESPE according to clause 5.2.1.4 of EN 415-10:2014 is not applicable one of the following safeguarding measures can be applied: a) Manual bypassing of ESPE: 1) In order to allow a pallet to pass through the ESPE when entering or exiting the hazard zone a hold-to- run control which bypasses the ESPE function shall be provided. 2) The hold to run control devices shall be mounted outside the hazard zone, not reachable from the hazard zone and in a position where there is a clear view of the hazard zone. 3) The hold to run control device shall start the conveying and bypass the function of the ESPE, the bypassing function shall have the same integrity as the ESPE function and shall provide a visual or acoustic signal indicating that the bypassing function is active.

4) The bypassing shall terminate if the conveying stops for any reason, if the hold to run device is released or the time taken for the pallet to exit the ESPE under normal operating circumstances is exceeded by 2 s.

5) An emergency stop device shall be positioned close to the hold to run device.

b) Combination of safeguarding devices for a sequential function

The feeding zone of the product shall be safeguarded by a combination of fixed and interlocked guards and ESPE according to 5.2.1.2 and 5.2.1.3 of EN 415-10:2014 (see fig. 19) performing the following functions:

1) When the pallet enters the intermediate area the outer safeguard (A) is triggered and switched to off.

2) Before the pallet (P) can get conveyed through the inner safeguard (E), the outer safeguard (A) shall be manually reset and thus release the movement of the pallet. When, while the pallet (P) is passing the inner safeguard (E), the outer safeguard (A) is still in the OFF-state or actuated, the palletizer shall stop all hazardous movements. This condition shall be maintained until manually reset.”

3) After the passage of the pallet (P), the inner safeguard (E) will be automatically reset only if the outer safeguard (A) has been manually reset.”

4) The manual reset device of the outer safeguard shall be mounted outside the hazard zone, it is not reachable from the hazard zone and is in a position where there is a clear view of the hazard zone.

5) for the use at discharge the sequence shall be vice versa.

Where a machine has more than one control zone for example separate control zones for the pallet magazine, lay pad magazine and palletizer the equipment covered by these different control zones shall be separated with one of the following:

a) Fixed guards dimensioned using table 2 of EN ISO 13857;

37

b) Automatic guards that move into place to separate one control zone from the other before someone enters one of the control zones;

c) AOPD which become active if someone enters one of the control zones; Some other form of ESPE that gives and equivalent level of safety protection

5.1.5.5 Resetting of interlocked guards

On machines where it is not possible to see the whole of the danger zone from the reset and start command , the requirement of 5.16.2.4 of 415-10: 2014 apply

Figure 19 Automatic feed

5.1.5.6 Variable width of pallet loads

When the width of pallet load can vary the following measures may be used as an alternative to the measures described in 5.1.5.4:

Systems according 5.2.1.3.13 (AOPD) of EN 415-10:2014 with additional vertical AOPD. The vertical AOPD safeguards the aperture while narrow pallet loads are passing. The distance between the fixture of the AOPD and the vertical AOPD and the distance between the vertical AOPD and the outer edge of the product shall not be greater than 300 mm (see figure 20) to prevent whole body access while the product is passing. Where the pallettizer produces several widths of pallet loads in order to maintain the required side gap between the pallet and the opening, the width of the pallet and its position on the conveyor shall be determined and it shall be possible to adjust the muting to maintain the required gap. The clearance between the vertical beams AOPD (H) and the outer edge of the product (P1, P2) shall not be greater than 300 mm. The clearance between two adjacent vertical beams AOPD at one side shall be not greater than 300 mm.

Keys: A outer safeguarding device C conveying device E inner safeguarding device G fixed guard H light beam L length of conveyor M reset device N intermediate area P pallet load Z hazard zone

38

The clearance between the outer edge of the product (P1, P2) and the fixture of horizontal AOPD or fixed guards shall not be greater than 230 mm. The clearance between the fixture of the AOPD (H) and the fixed guard (G) shall not exceed 180 mm Instead of a vertical AOPD an automatically movable guard with the same function can be used.”

Figure 20 Aperture with additional vertical AOPD

5.1.7 Release from trapping

Requirement 5.2.1.5 of EN 415-10: 2014 apply

5.1.8 Stability of machine

Requirement 5.2.3 of EN 415-10: 2014 apply

5.1.9 Pneumatic and hydraulic equipment All pneumatic components and piping shall conform to the requirements of EN ISO 4414. All hydraulic components and piping shall conform to the requirements of EN ISO 4413.

Where control functions are performed by hydraulic or pneumatic systems, these circuits shall comply with the requirements of 5.14. and 5.15.

5.1.10 Measures against falling from height

For palletizers with regular access to high level e.g. with product entry, grouping and transfer unit or pallet on high level the following requirements apply:

1) Preferably the machine shall be designed so that all points of regular access can be reached from floor or other safe level. Where access on high level is foreseeable, 5.2.2.3 of EN 415-10:2014 applies.

G = fixed guards C = conveyor H = vertical AOPD beams B = beams P = pallet load

H G G

B

C

P

39

2) For grouping and transfer unit higher than 1.200 mm, guards against fall from height shall be provided. Where parts of the machine are designed to prevent fall from height, no additional railing is necessary.

3) Where falling cannot be prevented by design or by fixed railings, automatic railings shall be provided taking precedence to the use of personal protective devices. When automatic railings are used, access to this zone should only be possible through interlocked guards with guard locking. The automatic railings should move to their guarding position before access can be gained.

Note: see also 5.4.1

5.1.11Electric equipment

Requirements 5.5 of EN 415-10: 2014 apply

5.1.12 Noise reduction

EN 415-10:2014 and EN 415-9 apply

Requirement 5.8 of EN 415-10: 2014 and EN 415-9 apply Annex B (normative) applies .

When designing machinery, the information and technical measures to control noise at source given in EN ISO 11688-1: 2009 shall be taken into account. Note: EN ISO/TR 11688-2: 2000 gives useful information on noise generation mechanism in machinery. Annex B (normative) give indication on how to select the measurement positions and the time interval for different kind of palletizers and depalletizers.

5.1.13 Conveyors

Requirements of 5.20.4 of 415-10 apply with the following additions

For roller or chain conveyor for pallet moving at a speed lower than 0,3 m/s it is possible to cross over the conveyor at the following conditions:

1) the crossing position shall be properly signed 2) the conveyors shall be provided with infill plates.

Where the width of the plates on roller conveyors is less than 80 mm a safety device shall detect the presence of a person while crossing and stop the conveyor. If this is not possible a bridge over the conveyor shall be provided.

3) if the conveyor is higher than 250 mm for the passages above the conveyor, steps complying with EN ISO 14122-3 shall be provided

4) if the conveyor is higher than 500 mm a hand rail shall be provided. A single hand rail on the side of the incoming pallet shall have a distance of 300 mm from the pallet or the pallet load to avoid crushing of the head.

5) an emergency stop device shall be reachable from each side the crossing point

Roller conveyor having a speed higher than 0,3 m/s and a step lower than 125 mm and any other kind of conveyors having a speed higher than 0,3 m/s shall be provided with infill plates and a safety device shall detect the presence of a person while crossing and stop the conveyor. If the safety devices are ESPE the distance from the conveyor shall be not less than 300 mm.

In this case the reset of the conveyor shall be from a position not accessible from the crossing point and the operator shall have a clear view of the crossing point from the reset position.

40

5.1.14Measures against risks from product

Clause 5.10.2.2 of EN 415-10: 2014 and the followings apply.

The risk of falling product shall be prevented by manufacturer .

Information on the condition of stability shall be provided in the instruction manual with reference to the speed of the conveyor and the friction coefficient of the product onto a pallet. Annex A (informative) presents a method for the evaluation of the stability of loads staked on a pallet.

Where a pallet could start from a waiting position in automatic mode while a person is crossing or staying on it, the waiting position of the pallet shall ensure a minimum time of 2 s to reach the crossing or access point. Reference to Clause 5.10.2.3 of 415-10:2014

5.1.15 Emergency stop and emergency switching-off Requirement of 5.14.5 of EN 415-10 apply

5.1.16 Control functions Requirements 5.14 of EN 415-10 apply

5.1.17Safety related stop functions Requirements 5.14.3 and 5.14.4 of EN415-10 apply 5.1.18 Safety related stops of variable speed electrical power drive systems Requirements 5.14.6 of EN415-10 apply

5.1.19 Stopping time Requirements 5.14.7 of EN415-10 apply. For calculation of the safety distances EN ISO 13855 applies

5.1.20 Partial or total failure of an energy supply The requirement 5.13 of EN 415-10 apply with the following addition:

When product is held by a vacuum, the following measures shall apply: 1) when the power supply fails, a suitable warning signal (e.g. audible or visual) shall be given.

2) the product shall be held long enough so that an operator can get out the hazard zone before the product is released. The time shall be ≥ 15 s,

3) if it is not possible to assure that the holding time is not according with 2) the access to hazard zone shall be allowed only after the load is released.

5.1.21 Unexpected start up

Requirement of Clause 5.16 of EN 415-10:2014. applies.

5.1.22 Requirements for remote control (teleservice)

Where the machine is equipped with functions for remote control (teleservice) which may affect the function or the safety of machine the manufacturer shall provide the means stated in 5.18 of EN 415-

41

10: 2014. If the panel for the control mode switch of the teleservice is different from the control panel of the machine it shall be located in a position with a clear view of the hazardous zone and will incorporate the stop control and an emergency stop. Tactile devices are only allowed for collecting data.

Note: Collecting data or monitoring machine parameters is not considered as teleservice.

5.1.23 Size or product changing

Requirements 5.20.6 of EN415-10 apply

5.1.24 Ergonomic design principles Requirements 5.11 of EN415-10 apply

5.1.25 Pallet load passing a fixed part

Where the presence of an operator is not intended but forseeable during normal operation and the product passes a fixed part closer than 500 mm one of the followings measures shall apply:

1) an impeding device not higher than the conveyor shall be positioned such that a person cannot stand at a distance less than 500 mm from the crushing points.

2) ESPE with a minimum PL c which shall stop the convejor’s movement when a person is detected. The minimum distance shall comply with ISO 13855 taking into account the part of the body exposed to the hazard.

3) by fitting a pressure sensitive edge to the fixed part complying with EN ISO 13856-2 which stops the conveyor with a minimum performance level c An emergency stop shall be available in the hazardous area . Depending on the size of the area a rope or bar may be used. The risk of impact may be considered negligible if the speed is less than 0,3 m/s.

5.1.26Requirement for operating stations on conveyor

When operating stations on conveyor is required for, e.g. the removal of packaging film or labelling a platform shall be provided according to 5.2.2.3 of EN 415-10: 2014. The dimension of the platform and infill plates shall be at least 600 mm larger than the foot print of the pallet.

The pallet approaching the working place shall stop and remain stopped during the manual operation and shall be started by a manual command positioned at a distance ≥ 1200 from any crushing point unless additional physical barriers prevent the actuation of the manual command from the crushing point.

5.1.27 Measures to prevent reasonable foreseeable misuse

Requirements 5.19 of EN415-10 apply

5.1.28 Prevention of risks derived from falling products during short time interventions

Risks from falling product shall be prevented by one of the following measures in the given order:

1) the products are held and not released during the operator intervention, e.g. by holding them in a positive mode; or

42

2) the products are deposited safely and energy supplies are isolated and stored energy is dissipated before the operator can access the hazardous area. Access shall be prevented by guard locking until these functions are completed or the products are prevented from falling. This can also be achieved by a device which is moved into position automatically or by the operator before entering the hazard zone.

3) When measures 1 and 2 are not applicable and it is necessary to operate from inside, a special operating mode shall be provided which allows the operator to access the hazard zone. Any machine operation shall be prevented and the hazardous energy shall be isolated. The instruction shall contain a description of the procedure to be followed to clear the situation.

5.1.29 Operations with open guards

Requirements 5.16.3 of EN415-10 shall apply

5.1.30 Stored energy

Requirements 5.17 of EN415-10 : 2014 shall apply

5.1.31 Radiation

Requirement of 5.9.1 and 5.9.2 of EN 415-10: 2014 shall apply

5.1.32 Measurements to control hazards generated by substances and materials

Requirement of 5.10.1 and 5.10.2 of EN 415-10: 2014 shall apply

5.1.33 Measures to control hazards generated by packaging materials

Requirement of 5.10.3 of EN 415-10: 2014 shall apply

5.1.34 Separation of hazard zone

For reasons of availability it may be desirable to keep parts of the machine running while operators stay in another area of the machine. In this case the different sub zones shall be separated by safeguards complying with 5.1.4 and 5.1.5 so that all hazardous functions of the accessed zone stop when a person moves from one zone to the other. Note: An example is given in 5.8.1

5.2. Safety requirement for semiautomatic stripper plate pallettizer

5.2.1 Ergonomic hazard

EN 1005-3 shall be applied but the maximum force when the operator pushes the product on a plane at a distance from the centre body shall not exceed 60 N. The machines shall be designed in a way that the layer forming plane can be adjusted to an adequate height for the operator taking into account EN 1005-4. If this is not reasonably practicable the instruction for use shall give information on the need of an appropriate platform for the operator. The instruction for use shall contain the information for the proper adjustment of the platform height. Note: the force exerted by an operator depends on the weight of the product and the friction coefficient between product and plane which can be kept as low as possible using a ball table or antifriction material. 5.2.2 Moving parts

43

All moving machine parts which are not in a clear view of the operator shall be guarded by fixed or interlocked guards or ESPE complying with 5.1.4. Guards at the product in-feed / grouping table are not necessary if the operator has a clear view to this hazard zone and the machine is operated by a two hand control with a hold-to-run function. 5.2.3 Safety related parts of control system

The safety related part of control system of the following safety function shall be designed for the minimum Performance level required (PLr)required

Safety function PLr Interlocked guard or ESPE d Stop of machine operation with hold to run control d Avoidance of unexpected start up d Emergency stop c

5.3. Safety requirements for automatic low level palletizer or depalletizer

5.3.1 Safeguarding of the of load lifting device For mechanical risks 5.1.4 and 5.1.5 apply 5.3.2 Mechanical locking system for lifting units

5.3.2.1 Automatic form fit devices

On palletizers where whole body access under lifting elements is intended for operation, or where the lifting mechanism is accessible without opening guards unexpected lowering of machine parts shall be prevented by at least one automatic device in a positive mode. These devices shall be driven into locking position when a safety related stop has been generated e.g by a spring force. This device shall be effective up to 150% of the maximum load situation. See figure 23 for examples of mechanical devices which lock a pallet or layer transfer lift platform. After the device has reached the locking position the lifting elements shall move not more than 100 mm (see figure 23). The automatic holding systems shall be activated in case of loss of energy. 5.3.2.2 Holding Brakes

On all other palletizers, lifting mechanisms shall be fitted with mechanical brakes which hold the mass of the element up to 150% of the maximum load situation. Where malfunction of these brakes leads to a machine standstill during the process, restart of the machine shall only be possible by an intended start command following a corrective action and reset. Where malfunction of these brakes does not lead to a machine standstill, these brakes shall be monitored by the control system. Any aberrant movement shall be signalled and lead to a stop of the machine. At the operator panel a notice shall be generated that warns of the risk to get under the lifted elements. Restart of the machine shall only be possible by an intended start command following a reset. Reset and restart after these stops shall only be possible in a lockable maintenance level. The monitoring shall be performed every time when the brakes are used. Where brakes are not used during the process they shall be monitored at activation of any safety stop.

44

The manufacturer shall describe the safe procedures and measures following this malfunction or alarm. This shall include how to move the lifting element to a safe position, prevention of any movement of the lifting element, safe access and save removal of load as well as the necessary maintenance of the brakes. Note: Accidents by spontaneous malfunction of holding brakes are not known yet. Usually malfunction of these brakes leads first to slow lowering of the lifted machine element. Therefore, the goal of the measures is to detect aberrant movement in order to prevent a dangerous malfunction of the brakes by maintenance. The fall of energy shall not prevent brakes to be activated. 5.3.3 Locking system for Maintenance and long term intervention

For maintenance or long term intervention under the lifting element one of the following measures shall be used in addition to 5.3.3:

a) A manually activated locking device activated in a positive mode shall be provided to prevent uncontrolled lowering of any lifted elements. Where holding brakes are used, a manually operated bolt can be used which shall be operable from a safe position. When it is not possible to check visually the position of the locking system a sensor shall detect the position of the locking device and warning will be available on the machine

b) A self-locking system shall be activated which prevent the movement of the device in a positive way. Typical devices are: backstops or rotating pins which limit the falling stroke to 100 mm maximum. The restrains shall be applied automatically and be effective at up to 150% of the maximum working load of the lifting elements and a sensor shall detect that the pin is engaged . See figure 21

c) If the machine is large enough and there is the risk that the machine could be started while some one is under the lifting device a manually operated restrain system shall be used with a locking system and the instruction shall specify the safety procedure. A warning light shall be activated when the restrain system is active

Keys: 1 lifting device 2 sensing device detecting the position of teeth 3 backstops 4 pins 5 rotating shaft with pins

Figure 21 Locking systems 5.3.4 Safety function of the machine

The safety related part of control system of the following safety function shall be designed for the minimum Performance level specified:

Safety function Plr Prevention of unexpected start up of vertical movement d

2

1 5

10

0 m

m

45

Stopping vertical movement of pallettizer d Stopping of pushing mechanism c Activation of mechanical fall arrester c Emergency stop c

5.4 Safety requirement for high level palletizer or depalletizer

5.4.1 Prevention of slip, trip and fall hazard

Requirement 5.2.2 of EN 415-10: 2014 shall apply with the following addition

When an operator need access to the hazardous area for maintenance, cleaning or removal of jam one or more of the following additional measures shall be used. The risk of falling from the platform at high level shall be prevented by the following means:

• Access stairs and platform shall comply EN ISO 14122-2 and EN ISO 14122-3. • Guards shall be fitted that prevent from falling • When it is not possible to provide guards in the platform at high level in all directions (for example

because there is the need to remove jam of products in the load) the instructions shall prescribe that personal protective device against the risk of falling shall be available in the platform and specify the correct working procedure. The machine shall be equipped with means to anchor the personal protective devices.

5.4.2 Safety measure against the falling of product.

When access underneath or next falling objects is possible during operations , product falling from the palletizer and the conveyors shall be prevented as follows: a) If the energy of an impact is less than 4 J and the presence of a person under the conveyor is not frequent by at least one of the following measures: • control of the acceleration e deceleration of the movement • stability of the load by means of intermediate layer to provide adhesion • controlling the position of the product and stopping the machine when a product out of position could fall b) When the energy of an impact is greater than 4 J the falling of product shall be prevented by mechanical devices which can hold the product.

5.4.3 Safety function of the machine

The safety related part of control system of the following safety function shall be designed for the minimum performance level required:

Safety function PLr Prevention of unexpected start up for vertical movement d Prevention of unexpected start up for stripper plate d Stopping vertical movement of pallettizer by a protecting device d Stopping of pushing mechanism by a protecting device c Activation of mechanical fall arrester c Avoidance of other unexpected start up c Emergency stop c

5.5 Safety requirement for automatic pick and place palletizer or depalletizer and column pick

and place palletizer

46

5.5.1 Prevention of slip, trip and fall hazard

Requirement 5.2.2 of EN 415-10: 2014 and 5.1.9 of this standard shall apply.

5.5.2 Measures for the protection from the falling of products.

Requirements of 5.4.2 shall apply.

5.5.3 Measures for the deposit or removal of layer pads

The deposit or removal of intermediate layers shall be done by means of equipment which prevent the operator coming into contact with movable parts. Where this is not possible the speed and force shall be minimized in order to avoid risks as follows: The speed shall be ≤ 0,2 m/s and the force ≤ 75 N If speed and/or force are greater the requirement 5.1.4 shall applies.

Note: see also 5.16


The safety related part of control system of the following safety function shall be designed for the minimum Performance level required:

Safety function PLr Stopping of movement of robot by a protecting device d limiting of motion of robot axis d Detection of movement of axis exceeding limits d avoidance of unexpected start up of robot d Emergency stop c

5.6 Safety requirements for robot palletizer or depalletizers

5.6.1 General

Robots for pallettizer or depalletizer shall comply with ISO 10218-1: and their application shall comply with ISO 10218-2 and the specific following requirements.

5.6.2 Robot axis limiting

Axis limiting shall be achieved by one of the following measures unless peripheral guards of the hazardous area are not reachable by the robot and its load at the maximum extension. Hazards due to the possible run out of the movement of robot shall be prevented in one of the following ways:

• the distance to the guards is greater than the maximun extension of robot movement • a limitation of movement of the axis shall be done according to 5.12 of ISO 10218-1 : 2011 • ESPE which detect robot axis and load limit and initiates a stop when exceeded shall be used. • distance guards shall be strong enough to resist to impact of product or packaging material.

Evaluation of resistance shall be done according to EN ISO 14120: 2015

5.6. 3 Requirement for operations inside the hazardous area

When is necessary that an operator enter the danger area for setting or the removal of a jam requirements of 5.1.29, 5.3.1- 5.3.4 shall apply.

47

When there are more than one robot is allowed to operate only one machine for once while the other are in a safe stop condition.

5.6.4 Requirement for operations inside the hazardous area Requirement for operations inside the hazardous area shall be comply with clause 5.6 (5.6.1-5.6.4) and 5.7 (5.7.1-5.7.4) of EN ISO 10218-1.



Safety function PLr Stopping of movement of robot by a protecting device d limiting of motion of robot axis d Detection of movement of axis exceeding limits d avoidance of unexpected start up of robot d Emergency stop c

5.7 Requirement for a case-packer palletizer

Requirement 5.6 shall apply.

Note: In order to assess the entire machine safety requirement for the section “case packer” can be found in EN 415-7

5.8 Requirements for multi station palletizer served by AGV

5.8.1 General

The machine shall be safeguarded by a combination of fixed guards, interlocked movable guards, and ESPE. The loading/unloading area shall be safeguarded by an AOPD (3) or AOPDDR complying with 5.1.5 or an AOPDDR as described in 5.8.2. Where the infeed product conveyor is not stopped by triggering the AOPD (3) or AOPDDR of the palletizer, it shall be designed inherently safe. Otherwise the conveyor shall be safeguarded by an additional AOPD (4) parallel to the product conveyor which shall be activated by triggering the inlet/outlet AOPD (3) or AOPDDR of the loading area (figure 22). The restart of the infeed conveyor after a safety related stop shall only be possible by a command initiated from outside the hazard zone of the conveyor and not accessible from there. The restart of the palletizer after a safety related stop shall only be possible by a command initiated from outside the hazard zone of the palletizer and not accessible from there. The operator shall have a clear view to the whole hazard zone from where he restarts the palletizer. Where the operator has no clear view over the whole hazard zone from the restart device in all situations, additional means for a clear view shall be provided (e.g. mirrors). If additional means cannot be provided or are ineffective the machine shall be restarted using one or more reset devices not accessible from the hazard zone which ensure that the operator can observe the hazard zone on his way from the reset devices to the restart device. In addition the following conditions shall be fulfilled for a clear view:

1. the distance between two pallets is more than 350 mm; 2. the height of the pallets is no higher than 1.1 m from floor level;

48

Key: 1 - conveyor 2 - pallet 3 – inlet/outlet ESPE (on access side) 4 – additional ESPE

Figure 22- Typical additional ESPE to

protect conveyors in a multistation palletizer

5.8.2 Access of AGV

AGV access to pick up or deposit pallets without stopping the palletizer is possible by muting the inlet/outlet ESPE under the following conditions: The access area during AGV access shall be safeguarded by two or more auxiliary detecting devices (AOPDDR)

- AGV is equipped with detecting devices (type AODPDR) which prevent the impact with a person and the possibility for a person to approach the AGV

- For each couple of AOPDDR only one AGV at a time may enter the hazard zone - Auxiliary AOPDDR operate to prevent the access of people into the danger zone. - If the AGV stops for any reason while entering the zone after a short time the control system is

activated and the palletizer shall stop - When AGV exits the hazardous zone the control system is reset

The access is permitted if all the following conditions are fulfilled:

a) When AGV approaches the access, the AGV control system sends a message to the multistation palletizer to request the access.

b) The palletizer checks that the AGV position is according to the requested mission. The check can be obtained by (see fig. 23 a).

- measuring the distance (a, c) of the AGV sides from 2 or more fixed points; - verifying that the free space between X1 and X2 is not greater than the AGV width more than

250 mm; W = L – (a + c) ≤ b + 500 mm - verifying that the free space between the front of the AGV and the inlet/outlet ESPE (e) is not

greater than 250 mm (see fig. 24-c);

49

Figure 23 a – AGV approaching the access point

Figure 23 b – Horizontal curtain for muting function

c) The entrance openings to the palletizing zone on both AGV sides are controlled by 2 or more AOPDDR placed in a way to create a continuous curtain on the side of the AGV

d) The horizontal curtain shall be height from floor lever not less than 250 mm and not more than 400 mm

e) The gap between AGV side and the curtain edge (f) is not greater than 250 mm.If the controlled area by AOPPDDR is vertical, the AOPPDDR shall according to clause 6.2.3 of ISO 13855

f) If the controlled area by AOPPDDR is horizontal, the AOPPDDR shall according to clause 6.3 of ISO 13855

Keys:

R1-R2-R3 – E1 – E2- E3 : AOPD

a – c : distance of AGV from the AOPD pillars

b – width of AGV

L = width of the front of multistation palletizer

e = free space in front of AGV

e

50

Figure 23 c – Vertical curtain for muting function



Safety function PLr Stopping of hazardous movements by a protecting device d Stopping of hazardous movement by auxiliary safety device to detect people access during AGV access

d

Emergency stop C Stopping of hazardous movements of the palletizer by a protecting device d Stopping of hazardous movement of the product in-feed conveyor by auxiliary AOPD c

switching of protective fields of AOPDDR d

unexpected start-up of palletizer d

unexpected start-up of conveyor c

5.9 Requirements for gripping head

5.9.1 Measures to prevent load falling

The load shall be positively supported by fingers designed as lifting component and having a safety coefficient of 4. When the fingers supporting the load use friction the pressure between the fingers and the loads and between the unit loads shall be enough to support 2 times the load. When it is possible that spillage of liquid or other materials can decrease the friction or the friction coefficient is unpredictable consideration shall be given to the spillage of the substance intended to be

51

palletized or depalletized and a test shall be performed in order to verify that 2 time the normal loads can be supported in the worst condition.

5.10 Requirements for vacuum gripping head

5.10.1 Requirements in the event of insufficient vacuum

In addition to 5.1.27 the following applies.

The pressure in the circuit near the suction cups shall be detected in order to prevent the lack of adhesion between the suction cups and the load due to worn suction cups or uneven surface of the loads. The pressure shall be monitored and the minimum value stated such that when the pressure is less than minimum value a warning signal shall be activated and the instructions shall inform the users of the need to stay away from the load supported. The minimum value of the pressure shall guarantee that the load is still supported for a minimum of 15 s.

5.10.2 Requirements when an operator requires access to equipment within the hazard zone

The control system shall prevent unexpected restart whilst an operator is clearing a jam, where fluid power is utilised this may require positive isolation and dissipation of energy prior to access being permitted.

5.11 Requirements for a magnetic gripping head

5.11.1 Requirement in case of loss of power supply

The magnetic gripping heads shall comply the following requirements: − only permanent magnets shall be used. The magnetic field shall be activated by an electrical current

that is not required to sustain the magnetic field. Demagnetization shall be activated only by electrical current.

− the magnetic clamping force shall be at least 3,5 times the maximum expected weight of the lifted products

− a visual signals of the magnetisation or demagnetisation status shall be fitted.

− manual magnetising/demagnetising shall be possible only if: � the function is selected by a switch, and � the palletizer is in the specific mode for manual load clamping/unclamping;

For palletizer, where whole body access to the hazard area is possible, the existing protective devices of the palletiser, that detect the presence of persons, shall prevent magnetization and demagnetization. The instructions shall warn the operator of the danger due to the magnetic force on ferromagnetic materials worn. (sign ISO 7010-P008) A warning shall state that no access for people with active implanted cardiac devices is allowed (sign ISO 7010-P007) The instruction shall provide information to prevent an incorrect use of the device; at least the following information are required:

- Full Surface Magnetic Force; - Min/Max dimensions of the contact area; - Minimum object thickness in the contact area - Requirements of material properties of the product to be lifted (ferromagnetic) - Surface properties of the product to be lifted (flatness, surface condition, presence of

indentation)

52

- Formula for the calculation of the anchoring force as function of the dimensions of the contact surface

- Formula for the calculation of the max allowable moment to prevent the overturning of the anchored object. (Only in case of a lateral anchoring).

5.12 Requirement for a roller curtain

When an operator requires access to equipment within the hazard zone for setting a jam or a malfunction hazardous movements of the roller curtain shall be stopped before an operator accesses the hazard zone. A command shall be easily available to prevent unexpected movement of the device while the operator is setting a jam or a malfunction.

5.13 Requirements for a pallet magazine

5.13.1 Requirement to prevent pallet falling

The machine shall have guides that prevent pallets from falling when the maximum possible height of the stack is more than 1,5 m or 1.5 multplied by shortest horizontal dimension whatever it is the smaller. Where the pallet magazine accepts pallets one at a time which are stacked automatically, the magazine shall be fitted with a high-level sensor to prevent the magazine being overloaded with pallets. Where the pallet magazine is loaded with a stack of pallets using a fork-lift truck and there is a risk of overloading, the magazine shall either be fitted with a top bar or cover to prevent overloading or a high-level sensor. Falling of pallets or tilting of the stack e.g. during loading of pallets or lowering of the stack shall be prevented by a sloped design of the upper or front end of the lateral guards. See Figure 24

Where the height of the pallet stack can be more than 1,5 m or 1.5 multiplied by shortest horizontal dimension whatever it is the smaller, the machine shall either:

• have guides that prevent pallets from falling or the stack from tilting or • falling of pallets or tilting of the stack during trouble shooting shall be prevented by providing a

manual control mode for all movements. These shall be performed by a hold to run control at low speed or step by step.

The instructions shall detail the procedure including • how to isolate the machine • the correct personal protective equipment that shall be worn (helmet, gloves, shoes) • the procedure for clearing jams

53

Figure 24 - Sloped lateral guards on pallet magazine 5.13.2 Measures against crushing and shearing Pallet magazine shall be guarded by a combination of fixed guards and, at the loading area, by interlocking guards or AOPD. The minimum distance s of the AOPD as shown in Figure 25 shall comply with Clause 5.1.4 of this standard. On semi-automatic pallet magazine that are loaded manually the loading area shall be guarded by an AOPD-curtain complying with EN IEC 61496-2 and positioned complying with EN ISO 13855. On semi-automatic pallet magazine where the pallets could be reached without stopping the movement, it is acceptable to reduce the risk of shearing of fingers or hands between the lowering pallet and the machine frame by a sloped design of the upper end of the lateral guards or by lateral guards as high as the maximum height of the stack but not higher than 2500 mm Unintended lowering of the pallet stack shall be prevented as described in 5.13.1

For pallet magazine which are not enclosed in guards, a self-locking lifting mechanism or automatic locking systems as described in b) or c) of 5.3.3 shall be used. The pallet magazine shall be fitted with a manual control which moves the lifting system. This shall be performed by a hold to run control at low speed or by limited movement. 5.13.3 Automatic start-up of an empty pallet magazine:

The area of the empty pallet magazine is separated from the adjacent machine (e.g. palletizer) by a fixed guard. The empty pallet is transferred to the adjacent machine through a slot shaped aperture in the guard, designed according to 5.2.1.3 of EN 415-10: 2014.

The feeding aperture of the pallet stacker shall be designed according to EN 415-10 Clause 5.2.1.3, for feeding the pallet stack. The safety distance s of the installed AOPD as shown in Figure 25 shall be positioned according to Clause 5.1.4 of this standard. An induction loop (“Induction loop I”). shall be positioned on the floor outside the hazard zone. Another induction loop (“Induction loop III”) shall be inserted inside the hazard zone.

25°-35°

150

mm

54

When a pallet transport vehicle enters the hazard zone, the AOPD shall initiate a safety related stop of the pallet stacker. When a vehicle approaches the aperture, the vehicle shall be detected first by the outside located induction loop and then by the interior induction loop. When the vehicle leaves the hazard zone, the sensors shall be released in reverse order. It shall only be possible to change the software or software parameters for the detection by the manufacturer. The machine shall only start automatically if the signals occur in the correct sequence given below, and if this is detected by the functional control:

1. Induction loop "I" is activated 2. AOPD "II" is activated 3. Induction loop "III" is activated 4. Induction loop "III" is released 5. Induction loop "I" is released Where it is possible that a person stays in the hazard zone while the automatic start is initiated, additional measures according to Clause 5.16.2 of EN 415-10:2014 shall be provided. Alternatively, the presence of a person shall be detected by a horizontally arranged light curtain or a safety scanner.

The method of automatic restart described in this clause shall only be used if all of the following pre-conditions are fulfilled:

• loading/discharge is performed only by manually operated fork lift trucks through the pallet feeding/discharge aperture

• the empty pallet magazine is separated from the hazard zone of other machines (e.g. palletizer) complying with 5.1.4 or 5.1.5.

• the operator (driver of the fork lift truck) has a clear view of the whole hazard zone of the pallet magazine

• the feeding area shall be in a clear view of the operator/driver of the fork lift truck so that no person can enter the hazard zone during the loading procedure.

Figure 25 Example of a pallet magazine with automatic restart

Key:

I =induction loop

II = AOPD

III = induction loop

S = safety distance

I

III

II

s

55



Safety function PLr Stopping of pallet magazine c Unexpected start up c

5.14 Requirements for a pallet changer

5.14.1 Requirement to prevent product falling

The design of the pallet changer shall prevent products from falling out while the machine is in motion by one of the following methods: a) provide guards against the projection of loads b) detect the presence of a person where products may fall and stop the machine. c) in case the falling of product may cause the spillage of dangerous product (e.g. chemicals, oil, powder) a dump tank shall be provided

5.14.2 Automatic pallet changer

Where the pallet changer works automatically it shall be safeguarded with fixed and interlocked guards or fixed guards and ESPE according to 5.1.3, and 5.1.4 Where the pallet changer operates using a hold to run control the machine shall be guarded on three sides with fixed guards dimensioned using table 2 of EN ISO 13857: 2008 and the controls shall be fixed in a position outside the danger zone where the operator has a clear view of the danger zone


The safety related part of control system of the following safety function shall be designed for the minimum Performance level required:

Safety function PLr Stopping of pallet changer c Unexpected start up d

5.15 Requirements for pallets grouping and ungrouping machines

5.15.1 Prevention of mechanical hazards

The hazard zone shall be safeguarded by a combination of fixed guards and AOPD as shown in figure 26. The area of the grouping/ungrouping unit shall be designed according to 5.2.1.3 of EN 415-10 for feeding/discharge of the pallet. The AOPD shall be positioned according to clause 5.1.4 of this standard

Note: annex A (informative) provides a method for assessing the stability of loads staked on a pallet

56

Figure 26 – safeguarding of a pallet grouping/ungrouping machine

5.15.2 Automatic start-up of grouping/ungrouping units

In order to avoid defeating of the AOPD because of inconvenient manual resetting the AOPD may be reset automatically. This method only applies for loading/discharge of pallets by a fork lift truck through the foreseen pallet loading/discharge aperture and with all of the following conditions fulfilled:

1. The feeding area and the whole hazard zone of the grouping/ungrouping unit shall be in a clear vision of the operator/driver of the fork lift truck so that no person can enter the hazard zone during the loading procedure undetected. If necessary this shall be assisted by the means described in Clause 5.16.2.2 of EN 415-10:2014

2. Where it is possible that a person enters the hazard zone through a means of access different from the loading/discharge aperture, these means of access shall be provided with means described in Clauses 5.16.2.3 and 5.16.2.4 of EN 415-10:2014

3. Suitable sensors, e.g. ultrasonic sensors, shall be used

4. These sensors shall be positioned and dimensioned so that they can clearly distinguish the fork lift truck from a person, e.g. the detecting fields of ultrasonic sensors shall not overlap or be positioned higher than 2,7 m.

F F

Key:

F= fixed guards

B = AOPD

C = AOPD with muting

B

C

57

5. For an automatic re-start the following sequence shall be followed:

a. When a fork lift truck approaches, the AOPD shall initiate a safety related stop of grouping/ungrouping unit.

b. all suitable sensors must have been activated for period of minimum 2 s and within a time of 5 s after the AOPD had been triggered

c. The sensors shall be released in reverse order, when the vehicle leaves the feeding aperture.

6. When the AOPD or the suitable sensors have been activated for 10 s or more, the automatic re-start shall be inhibited and a manual re-start shall be necessary

7. When the suitable sensors do not observe an object in their detection field within the expected period after triggering the AOPD, the automatic re-start shall be inhibited and a manual re-start shall be necessary

8. Automatic re-start shall only shall only be possible if the signals occur in the correct sequence

9. It shall only be possible to change the software or software parameters for the detection by the manufacturer.

Figure – 27 Pallets grouping and ungrouping

58

5.16 Requirements for layer pad inserting or removing

5.16.1 Measures to prevent risks when loading or unloading layer pad

The insertion or removal of layer pad in the situation of figure 16 a) may be done while the machine is running provided that during the time when the upper limbs of the operator enter the inside zone the movement of the device which remove or deposit the pads is away from the magazine. To perform the task the operator opens an interlocked guard which stops the machine only if the automatic device approach the magazine at a distance reachable by the operator.

As alternative while the layer pad magazine is being filled or emptied, the guards around the layer pad magazine shall be designed so it is not possible to move from the layer pad magazine area into the operating machine.

When the arm approaches the magazine, if the speed is lover than 0,3 m/s it and there is not a severe risk of crushing it is possible to activate a lamp that warns the operator.

5.16.2 Measures when layer pad inserting or removal is done by a robot

Robotized system for the insertion or deposit of layers sheet shall be safeguarded according to clause 5.1.4. Robot shall work in the inside area, the layer is taken and deposited by the robot in a magazine through a narrow slot. The dimension of the slot and the distance of hazardous points shall be according to EN ISO 13857 the operator can manually remove the layer from the magazine.



Safety function PLr Stopping of layer remover c Unexpected start up c

5.17 Requirements for a pallet size or weight checker


If the speed of pallet is lower than 0,3 m/s , there is not risk of loss of stability of the load and the distance between the load and the fixed part of the checker is ≥ 500 mm there is no need of perimetral guards. If the above condition are not met requirement 5.1.4 and 5.1.5 apply.

Note: Annex A (informative) presents a method for assessing the stability of loads staked on a pallet

Requirements for a pallet condition checker

5.18.1 General

The design of the machine shall ensure that broken bits of pallets are not trapped inside the machine and that the machine can be easily cleaned.

5.18.2 Measures to prevent risks from the moving part of machine

59

Moving parts shall be safeguarded using fixed and interlocked movable guards according to 5.1.4 and 5.1.5 The design of the guards shall take into account the risk of broken pieces of pallet being ejected. The safety related part of control system shall comply with PL “c” of EN ISO 13849-1.

6. Verification of safety requirements and measures

6.1 General Clause 6 of EN 415-10 applies entirely. Electrical verification shall include: - Verification that the electrical equipment complies with its technical documentation - Verification of continuity of the protective bonding circuit - Protection against residual voltage - Functional tests - In case of protection against indirect contact by automatic disconnection according to 18.2 of IEC

601204-1: 2016 - Verification that the relevant part of clause 8.2.6 of IEC 60204-1: 2016 are met 6.2 Verification procedures Verification procedures for each safety requirements detailed in 5 are shown in table 5

Safety

require

ment

Visual

inspe

ction

Functio

nal test

Measur

ement

Calcula

tion

Safety

requir

e

ment

Visual

inspe

ction

Functio

nal test

Measur

ement

Calcula

tion

5.1.2 x x x 5.3.3 x x x 5.1.3 x x x 5.3.4 x 5.1.4 x x 5.4.1 x 5.1.5 x x 5.4.2 x x x 5.1.6 x x 5.4.3 x 5.1.7 x x 5.5.1 x x 5.1.8 x x 5.5.2 x x x 5.1.9 x x 5.5.3 x x x 5.1.10 x x x x 5.5.4 x 5.1.11 x x x 5.6.1 x 5.1.12 x x x 5.6.2 x x x x 5.1.13 x x x x 5.6.3 x 5.1.14 x x x 5.6.4 x 5.1.15 x x 5.6.5 x 5.1.16 x x x 5.7 x x 5.1.17 x x x 5.8.1 x x x x 5.1.18 x x x 5.8.2 x x x x 5.1.19 x x 5.8.3 x 5.1.20 x x 5.9.1 x x 5.1.21 x x 5.10.1 x x 5.1.22 x x 5.10.2 x 5.1.23 x x x 5.11.1 x x x 5.1.24 x x x 5.12.1 x x 5.1.25 x x x 5.13.1 x x x 5.1.26 x x 5.13.2 x

60

5.1.27 x 5.13.3 x 5.1.28 x x 5.14.1 x x 5.1.29 x 5.14.2 x 5.1.30 x x x 5.14.3 x 5.1.31 x x x 5.15.1 x x 5.1.32 x x x 5.15.2 x x 5.1.33 x x x 5.16.1 x x x 5.1.34 x x 5.16.2 X x 5.2.1 x x x 5.16.3 x 5.2.2 x x 5.17.1 x x 5.2.3 x 5.18.1 x 5.3.1 x x 5.18.2 x x 5.3.2 x x x x

7. Information

7.1 General

The requirements of part 7 of EN 415-10: 2014 apply entirely

7.2 Instruction

7.2.1. General

The requirement of 7.4.1 of EN 415-10: 2014 apply entirely with the following additions

7.2.2 Quality requirement for pallets

The instruction manual shall specify that the good quality of the pallet is essential for the safety and efficiency of machine. The manufacturer shall specify the kind and quality of pallets which can be handled by the machine

7.2.3 Personal protective equipment

Instruction manual shall specify the personal protective equipment necessary for different kinds of operation in order to reduce the residual risk with reference to the applicable standards.

7.2.5 Instructions for the transport and lifting of machines and part of machines.

Large machine are disassembled during the shipment and assemble in the working place. Part which is not stable shall be prevented from falling by means of stirrups, clamps, rods, bars and similar. The instruction shall recommend keeping those parts for future use. The instruction for the transport and lifting shall be posted directly on the parts or on the crates

61

Annex A (informative): Method for assessing the stability of loads staked on

a pallet

In the presence of horizontal forces, the stacked load can become unstable and risks of slipping and / or overturn can arise. Figure A1 – Instability of a stacked load A-1 Prevention of slipping To prevent the slipping of a load, the horizontal force “F” shall be limited to the value

F ≤ (M * g * f ) / 2 Where :

M = mass of the product g = gravity f = friction coefficient F = force which causes instability = 2 = is assumed as “safety factor”

The friction coefficient (f) can be determined with an inclined plane assuming that f = tang ɑ; where ɑ is the minimum angle of inclination that allows the movement of the product, providing the surfaces in contact have the same friction coefficient of the stack A-2 Prevention of overturn To prevent the slipping of a stacked load, the horizontal force Ft shall be limited to the value

F/M*g < aG / (2*hG) Where : F = force which causes instability

M = mass of the product g = gravity aG = horizontal distance of the gravity centre from the edge of the pallet in contact with the

support hG = vertical distance of the gravity centre from the contact border point 2 = is assumed as “safety factor”

key

A = layer sheet

62

Figure A2 – Overturn of a stacked load

A.3 Evaluation of the horizontal forces (inertia effects) The force of inertia F, aging on the product, shall be determined using the following criteria A.3.1 Stopping/starting acceleration

The force of inertia F shall be determined by the following formula: F = M * V/t

Where : M = mass of the product, not stabilized in the stack, V = speed of the product which could fall, t = the smallest between stopping time and acceleration time at the starting

A-3.2 Centrifugal force

In case of movement of the pallet in curve or on a rotating table, the centrifugal force F shall be determined by the following formula:

F =M * V2/ R where: R = the radius of the curve A.3.3 General case

In case it is possible that the pallet stops in curve, the horizontal force F shall be determined by the following formula:

F = M* √ (V/t)2 + (V2/R)2

63

Annex B (normative) – Microphone positions when measuring noise

pressure level emitted by palletizers and depalletizers According to the type of installation the main source of noise can be in a defined position or movable in dependence of the phases of operation. 1) Noise sources in a defined position

This this situation is normally ascertainable in the following kind of palletizers and depalletizers: • Low level • High level • Pick and place • Column pick and place • Case packer palletizer

The measuring position shall be in a perimeter around the machine at a distance of 1 m from the hazard zone normally enclosed by fixed and mobile guards or ESPE.

Normally the machine has a regular square or rectangular profile. Sometimes the profile shows irregularities with protruding parts or recesses . Projecting parts from the profile of the machine, not relevant as emitters of noise, shall be neglected and the measuring position shall be 1 m from the regular profile of the machine. If the protruding part is a noise emitter the measuring position shall 1 m from this part. See fig. E1 which saw an example of measuring positions.

Keys:

Arrows: 1 m distance of the measurement positions A: projecting part from the profile; noise emitted negligible B: projecting part from the profile; noise emitted not negligible

C: recess

Figure E1 – Example of microphone positions

The number of measuring positions shall be unless 4 plus 1 in the operator position which is normally close the control panel. The distance between the measuring positions will be chosen so that the difference between the measured noise level in two contiguous points is less than 2 dB(A). 2) Main noise sources moving in various positions In palletizers and depalletizers where the main noise sources are not in a fixed position but can take various positions in dependence on the phases of the operating cycle (picking, moving, change of position, deposit of product etc.) and this affects the noise levels in the measuring positions, if the cycle

B

A

C

64

time is long and 3 consecutive cycles last longer than 5 min) it is impracticable to spend a long time for every measuring positions. In this case the following procedure shall apply: • the measuring position shall be in a perimeter around the machine at a distance of 1 m from the

hazard zone normally enclosed by fixed and mobile guards or ESPE. • the different position of the main noise sources shall be identified • Noise is measured in all measuring positions with the main source of noise in various positions shall

be performed . a separate report shall be drafted for every Keys: Arrows: 1 m distance of measurement positions A: main noise source B: alternative position of main noise source C: perimeter of the palletizer C B A

Figure E2 – Example of microphone positions with two main sources of noise alternatives

3) Measurement time interval When the noise emission is not steady the measurement time interval shall be carefully defined and reported in the test result. An integral number of consecutive cycles shall be considered. The number of cycles shall be determined in order to reach a complete contribution of all the noise sources and typically shall be not less than 3 complete cycles. 4) Peak emission sound pressure

The greatest absolute emission sound pressure C-weighted (Lacebark) shall be determined with the same measurement time interval.

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Annex C ( informative) – Design criteria for the safety of multi station

palletizer served by AGV

The following measures have the aim to give a positive contribution to the safety of multi stations palletizing system and is recommended to the manufacturers to take in consideration: 1) the palletizer should provide an enable signal for the feeding machine a warning for possible saturation or absence of product. 2) an automatic buffering should be inserted between the feeding line and the palletiser. As alternative to

an automatic buffering of product, the instruction should give information on how to avoid frequent stop

and start of the feeding machine information on how to avoid frequent stop and start of the feeding machine.

3 the palletizer should be able to handle the foreseeable dimensional variability of product , waste product

or product missing the identification) to avoid production stops (egg. by means of a dedicated pallet to

collect those products). 4) the choice and the design of gripping equipment should give attention to the reliability of the equipment in order to minimize the need of human intervention 5) te gripping equipment should be adaptable to irregular size products 6) the machine should be provided with an automatic auxiliary equipment to perform other operations

like insertion of layer sheet or movement of empty pallet avoiding as more as possible the interaction between operator and machine .

7) The characteristic of an AGV suitable to operate with a multi station palletizing system should be indicated

by the manufacturer of the system with regard to:

• The measures to prevent people enter the palletising area during the AGV intervention • the measures against the risk of crushing or impact between operator and AGV • the characteristic of interface and signals to be exchanged between AGV and palletizer shall be stated by the manufacturer of palletizer

Annex D (informative) – Safety aspects for integrated palletizing system This standard EN 415-4 is addressed to manufacturers of palletizers and depalletizers but recognize that, especially for integrated palletizing system, the overall safety depends very much on an adequate flow of information between all the part involved which are often much more than the manufacturer and the user. This informative annex is aimed to remind the tasks to be performed and establish correct relationship between the parts involved. When various machines or partly completed machines of an integrated palletizing system are supplied by

different manufacturers the end user or the integrator, appointed by the end user, shall be responsible to

perform the above tasks:

a) clarify how to deal with machinery and equipment provided and define the intended use of the

installation (kind of product to be packed, environmental conditions etc.) b) define the lay out and the spaces c) define the entry and exit points for material and operators

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d) define the sub-zone and the segregation in order to put sub-zones in safety while the other are in operation

e) define contractually which additional documentation is to be supplied so that subsequent changes can be implemented more easily.

f) define, as far as possible, the usage of important harmonized EN standards as reference and agree the procedure in the event of deviations from harmonized standards.

g) give to manufacturers of machines and equipment the necessary information for a coherent application of the safety related parts of control systems to all machines and equipment involved

h) define the performance level (EN 13849-1) or safety integrity level (EN 62061) when the safety related parts involve several machines i) define the range of actions of the emergency stop function of the various machines j) define the interface between machines and equipment k) define a procedure for the escape and rescue of trapped person l) verify that the strategy for risk reduction be done according to EN ISO 12100:2010 and the

information for use cover all the machine and equipment m) define for machines and equipment which can be part of the installation only at times the

procedures for the inclusion or exclusion n) define the position of the supplies of energy o) define the procedure for the overall check of the conformity

When the various machines which form integrated palletizing system are supplied by different manufacturers shall be responsibility of the end user or of the integrator appointed by the end user to perform the above tasks. In this situation the manufacturers of parts (machines or partly completed machines) of the integrated palletizing system shall take part in the flow of information between the integrator, user and other suppliers. It is strongly recommended that all the parts involved make sure to have a good knowledge of all the necessary information. The standard ISO 11161: 2008 specify safety requirement for integrated manufacturing systems that incorporate several interconnected machines for a specific application.

Annex ZA (informative)

Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC

This European Standard has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association to provide a means of conforming to Essential Requirements of the New Approach Directive 2006/42/EC on machinery.

Once this standard is cited in the Official Journal of the European Communities under that Directive and has been implemented as a national standard in at least one Member State, compliance with the normative clauses of this standard confers, within the limits of the scope of this standard, a presumption of conformity with the relevant Essential Requirements of that Directive, except essential requirement 2.1.1, and associated EFTA regulations.

Only the parts of EN 415-10 clearly referred in this standard are required to achieve the presumption of conformity to Machine Directive

WARNING — Other requirements and other EU Directives may be applicable to the product(s) falling within the scope of this standard

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The following list shows additional standard which may be useful:

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body

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EN 13856-2: 2013, Safety of machinery - Pressure-sensitive protective devices - Part 2: General principles

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EN 12198-1:2000 + A1:2008, Safety of machinery — Assessment and reduction of risks arising from

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radiation emitted by machinery – Part 2: Radiation emission measurement procedure


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68

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EN 60825-1:2014, Safety of laser products — Part 1: Equipment classification and requirements

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visual, auditory and tactile signals

EN 61310-3:2008, Safety of machinery; Indication — marking and actuation — Part 3: Requirements for

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EN ISO 13732-3:2008, Ergonomic of the thermal environment — Methods for the assessment of human

responses to contact with surfaces — Part 3: Cold surfaces

EN ISO 13849-2: 2012- Safety of machinery — Safety related parts of control systems — Part 2:

Validation

EN ISO 13850: 2016, Safety of machinery — Emergency stop — Principles for design

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for design and selection

EN 14120: 2015, Safety of machinery — General requirements for the design and construction of fixed

and moveable guards

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plants — Part 1: Choice of a fixed means of access between two levels

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Documents

FINAL DOCUMENT AFTER WG3 MEETING ON 3-4 … · EN ISO 14122-3: 2016 - Safety of machinery — Permanent means of access to machines and industrial plants — Part 3: Stairways, stepladders