Types of Protective Measures The Expert Area

Safely Muting an Industrial Process

Denition
Muting is a temporary bypassing of the protective function of a light curtain and is permitted only during the non-hazardous portion of the machine cycle. Machine control systems which initiate muting must be control reliable. When used properly, muting can help accelerate industrial processes while protecting personnel from potentially hazardous situations. Processes where muting applications can be found include, but are not limited to, metal forming, conveying, robotic assembly or palletizing, and automated assembly lines. ANSI standard B11.19-2010 clearly explains the requirements for muting: Muting of the device shall be permitted during the non-hazardous portion of the machine cycle. Muting of the device shall be accomplished such that a single failure of a component, a subassembly or a module of the system/device that affects the performance of the command from being initiated, or shall cause an immediate stop command. In the event of a failure, reinitiation of the machine shall be prevented until the failure is corrected or the system or device is manually reset. In the presence of a failure, repetitive manual reset of the system or device shall not be used for production. If the machine has reversing capability where a muting hazard is possible, the control system shall include an automatic means so muting is only permitted in the forward direction. If an individual can pass through a sensing eld when the device is muted, means shall be provided to ensure that the individual is outside the hazard area, or that the machine ceases hazardous motion when the muting is removed. [clause 8.3.2.5]

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The OMRON Automation and Safety Muting Solution
OMRON Automation and Safety offers a selection of control-reliable solutions for muting: the F3SJ-A with built-in muting; the MS4800 with RM-6; and the RM-3 which works with a variety of safety light curtains.

Requirements for Use of Muting

Many different standards exist which explain the requirements to consider when implementing a muting system. The following list, while not complete, was compiled from a review of ANSI B11.19-2010, EN692-1994 and IEC 61496-1. Muting of a light curtain is permitted only during the non-hazardous portion of the machine cycle. If the machine tool has reversing capability where a muting hazard is possible, the control system shall include an automatic means through which muting is permitted only in the forward direction. There must be at least two, independent, hard-wired muting signal sources, of the same level of safety integrity as the light curtain. A single, simple, camoperated limit switch is inadequate as a muting signal source since its failure can remain undetected. The position of the muting signal source must be secured against unauthorized adjustment. The machine control system and associated muting circuitry must be control reliable. The list above is not a complete guide to muting standards. The employer must contact the appropriate local safety agencies for specific requirements regarding their machine and safety-related control system. Omron has provided the information above for reference only and makes no claim regarding its accuracy, completeness or effectiveness for a specific application.

The Real World

So what does the real world look like? Lets take a simple application and illustrate some of the muting options available when using solutions from Omron. The application involves the safe exit of a full pallet from a palletizing machine where it has just been loaded and shrink wrapped by a fast-moving (and potentially dangerous) robotic system. The robotic work cell is typically guarded by interlocked fencing, while a safety light curtain guards the opening where the full pallet will exit on a conveyor. The goal is to allow the pallet to exit the work cell without tripping the light curtain, stopping the system and slowing the production process. Figure 5.18a illustrates a system where two through-beam sensors, arranged in an x pattern, are used as the muting inputs. This system is bidirectional which means that the light curtain will be successfully muted whether the object approaches from the left or the right. Sensor A must be a dark-on type sensor with a PNP-type output or a switch that closes its contacts to provide +24 VDC when it is OK to mute. Sensor B must be a light-on type sensor with a PNP-type output or a switch that opens its contacts when it is OK to mute. In this two-sensor system, the sensors must transition to the on state within 3 seconds of each other for the muting state to occur. Bidirectional systems can also be constructed using four mute sensors.

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Types of Protective Measures The Expert Area

Fig. 5.8

Fig. 5.18a

Fig. 5.18b

Sensor A

Light Curtain

Sensor A

Light Curtain

Pallet

Conveyor Bi-Directional

Pallet

Conveyor

Sensor B

Light Curtain Light Curtain

Sensor C

Sensor B Sensor A

Light Curtain Light Curtain

Sensor A

Pallet

Sensor B

Light Curtain Light Curtain

Sensor C

Sensor B Sensor A

Light Curtain Light Curtain

Sensor A

Pallet

Sensor B

Light Curtain

Sensor C

Sensor B

Light Curtain

What if you only want the light curtain to be muted when the pallet approaches the safety light curtain from one direction (unidirectional)? Take a look at Figure 5.18b. Although similar in appearance to the application above, sensor C has been added to detect the pallets direction of travel. Sensor C must be a dark-on type sensor with a PNP-type output or a switch that closes its contacts to provide +24 VDC when it is OK to mute. Sensor C must transition to the on state at least 0.05 seconds prior to activation of sensors A and B. Sensors A and B must transition to the on state within 3 seconds of each other and sensor C must turn off before sensors A and B turn off.

Bypass-Allowed function
Did a pallet fall off the conveyor? Did the conveyor unexpectedly stop? Did the sequence of processing operations not occur in the correct order to allow an automatic transition to the muted state? When these types of issues are encountered the bypass-allowed function is a real lifesaver. This function allows supervisory personnel to momentarily override the machine stop signal and enter the mute state. While very useful, this feature must be used with appropriate caution and guidelines from ANSI B11.19-2010, EN692-1994 and IEC61496-1

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