Machinery Safety

Code:

M.EM072

Acronym:

SM

Keywords
Classification	Keyword
OFICIAL	Automation

Instance: 2021/2022 - 1S

Active?	Yes
Responsible unit:	Automation, Instrumentation and Control Section
Course/CS Responsible:	Master in Mechanical Engineering

Cycles of Study/Courses

Acronym	No. of Students	Study Plan	Curricular Years	Credits UCN	Credits ECTS	Contact hours	Total Time
M.EM	10	Syllabus	2	-	4,5	39	121,5

Teaching language

English

Objectives

The main objective of this curricular unit is to provide the students with the fundamental concepts of machinery safety and design. To achieve this the curricular unit starts with two topics that cover the fundamentals of safety philosophy and the fundamental methodologies of risk assessment and reduction. In the second part of the course three topics introduce increasingly complex technical devices/systems which will give the student the fundamental tools for safety machinery design. The final topic addresses safety design approaches for reference machinery.

Learning outcomes and competences

Learning outcomes and competences:

1. Identify common hazards that occur with machinery and make them safe.


2. Describe the typical and widely used regulations for Safe Machinery use and understand the Regulations that apply to manufacturers and users of equipment.


3. Develop the ability to check for hazards, conduct risk assessments and determine the risk reduction requirements for any machinery problem.


4. Through systematic design methods, convert the initial requirement for a safety control function into a practical design compliant with the standards.


5. Understand the basics of functional stops, E-stops, basic principles of safety relays and the essential circuits arrangements for meeting safety categories.


6. Understand the basics of Safety PLC’s and Safety industrial communications and know how to use them in machinery design.

Working method

Presencial

Pre-requirements (prior knowledge) and co-requirements (common knowledge)

Students with special status may choose to attend the Course as if they were ordinary students, by submitting themselves to the norms of their evaluation.
Alternatively, students with special status must complete a global test consisting of a written test (50%) and an oral test (50%).

Program

1. Machinery safety




1. Introduction of machinery safety, principles and strategy
   
   
   
   1. Design considerations.
   
   
   2. Machinery safety designer responsibilities and product liability.
   
   
   3. Guarding strategies
   
   
   4. Introduction to hazards and risks
   
   
   
   


2. Overview of regulation and standards




1. European Machinery directive.


2. New approach directives


3. Different type of standards


4. CE Marking


5. Test bodies, insurances and authorities






2. Risk assessment, risk reduction




1. Introduction to risk assessment


2. Functions of the machine


3. Identification of hazards, risk estimation


4. Risk reduction – Safe design


5. Risk reduction – technical protective measures


6. User information for residual risks


7. Documentation methods for the risk assessment




3. Guarding techniques




1. Design procedures for safety controls.


2. Mechanical guarding.


3. Interlocking devices.


4. Emergency stop monitoring and safety relay


5. Sensors and devices for machinery protection




4. Safeguarding systems




1. Mechanical safety arrangements


2. Electrical safety circuits


3. Hydraulic safety circuits


4. Pneumatic safety circuits




5. Programable systems for safety controls




1. Safety PLC’s


2. Safe networking communication


3. Standards for programmable systems (SIL)




6. Reference machinery




1. Safety in lifting equipment.


2. Safety in press- brakes.


3. Safety in robotic work-cells.

Mandatory literature

John Ridley; Safety with machinery. ISBN: 0-7506-6780-X
MacDonald, D; Practical Machinery Safety,, Elsevier, 2004

Complementary Bibliography

Smith, David John; Functional safety :. ISBN: 0750662697
Hedberg, J., Söderberg, A., Tegehall, J ; How to design safe machine control systems – a guideline to EN ISO 13849-1, , SP Technical Research Institute of Sweden, 2011
Adams, F, Schmidt, F, ; The best of MRL news, Safety on Machinery and Machine Control Systems, SCHMERSAL, 2011
Sick GmBh; Guide for Safe Machinery, Six steps to a safe machine, Sick GmBh, 2019

Teaching methods and learning activities

The contact time of the course will be held in 2 theoretical-practical classes of 1.5 hours that will address the course program with the combination of (1) exposure of theoretical content using audiovisual support, (2) practical  exercises that will allow the consolidation of the knowledge taught, (3) laboratory demonstrations using industrial equipment and software. Given the nature of points 2, 3 and 4 of the discipline's program, which focus on risk analysis, protection techniques and systems respectively, theoretical and practical exercises will be primarily used. Point 5 of the course's program is focused on software applications for security systems, so classes of demonstration / experimentation of systems in relevant laboratory environment will be used. In point 6 of the course program, students will be asked to carry out work for the design and safety analysis of  industrial equipments. This work is mostly performed autonomously  in groups and will take place over 4 weeks, during which 3 TP classes are reserved for the monitoring of the work by the lecturer. Through the MOODLE-UP platform, the contents of the study elements and support of TP classes are made available. . A set of documents with technological information from different manufacturers are also available, covering the various topics covered. The attendance of students by the teachers exists throughout the semester at a pre-established time.

keywords

Technological sciences > Technology > Safety technology

Evaluation Type

Distributed evaluation with final exam

Assessment Components

Designation	Weight (%)
Exame	50,00
Trabalho prático ou de projeto	50,00
Total:	100,00

Amount of time allocated to each course unit

Designation	Time (hours)
Apresentação/discussão de um trabalho científico	1,50
Elaboração de projeto	34,00
Estudo autónomo	47,00
Frequência das aulas	39,00
Total:	121,50

Eligibility for exams

To be admitted to exams, students have to be enrolled in the course and not exceed the absence limit allowed in the General Evaluation Rules of FEUP.

Calculation formula of final grade

The final classification of ordinary students is based on one written test (PE) and a research project (TRB). These components are evaluated from 0 to 20,  with the following weights: (50%)PE - Individual written test, without consultation, to be carried out at the time of examinations. (50%) TRB - Research Project with presentation and discussion to be carried out on the last week of classes. The final classification of the research work (TRB) is based on the produced report, and the final presentation and discussion to be carried out with all the elements of the research project group.

Final Classification=0,5*PE+0,5*TRB

Important remark: Students must achieve a minimum grade of 7 out of 20 in PE. Even if students achieve a grade of 9,5 out of 20 on the final classification, but don’t achieve 7 out of 20 on PE, they will earn a grade of 9 out of 20. - If students miss one of the written exams, they will earn a 0 out of 20. - If students don’t accomplish the research project, they will earn a 0 out of 20. - Students can only attend the final exams (PE) and to the research project if they attend to classes (except students with a special status – according to General Evaluation Rules of FEUP) 

Special assessment (TE, DA, ...)

The students with special status may choose to attend the course as ordinary students, submitting themselves to a similar evaluation.
In alternative, the student must be submitted to one written exam that represents 75% of the final classification and a oral exam that represents the other 25 % of the final classification.
However, to get access to the oral exam, the student must have a result equal or superior to 7 marks (in 20) on the written exam.

Classification improvement

Students wishing to obtain an improvement in grading may, at the time of appeal, submit a written test (PER) on the overall subject of the UC that will replace PE. The final grade is obtained according to:

Final grade (improvement) = 0.5 * PER + 0.5 * TRB

The classification of the TRB work performed is maintained.

Observations

https://videoconf-colibri.zoom.us/my/germanoveiga