Mechatronics

Module 7: Commissioning, Safety, Teleservice Textbook

(concept) Matthias Rmer
Chemnitz University of Technology Institute for Machine Tools and Production Processes

EU-Project Nr. 2005-146319 MINOS, duration from 2005 to 2007 European Concept for the additional Qualification Mechatronic of skilled Personnel in the globalized industrial Production.

The project was developed by the European Union within the action program of the European Union for vocational education Leonardo da Vinci.

www.tu-chemnitz.de/mb/WerkzMasch

Teach ware concept working out and proving project partners Chemnitz University of Technology, Institute for Machine Tools and Production Processes, Germany Project Management Corvinus University Budapest, Institute for Information Technologies, Hungary Stockholm University , Institute for Sociology, Sweden Wroclaw University of Technology, Institute for Industrial Engineering and Automation Technologies, Poland Henschke Consulting Dresden, Germany Christian Sthr Unternehmensberatung, Germany Neugebauer and Partner OHG Dresden, Germany Korff Isomatic sp.z.o.o. Wroclaw, Poland Euroregional Chamber of Industry and Commerce Jelenia Gora, Poland Dunaferr Metallwerke Dunajvaros, Hungary Knorr-Bremse Kft. Kecskemet, Hungary National Institute for Vocational Training Budapest, Hungary

Teach ware concept: Manual, exercises and solutions books for Module 1: Fundamentals Module 2: Cross-cultural Competencies, Projectmanagement Module 3: Fluidics Module 4: Electrical Drives and Controls Module 5: Mechatronic Components Module 6: Mechatronic Systems and Functions Module 7: Commissioning, Safety, Teleservice Module 8: Remote Maintenance, Diagnosis

Further information:
Chemnitz University of Technology Institute for Machine Tools and Production Processes Univ.-Prof. Dr.-Ing. habil. Prof. E.h. Dr.-Ing. E.h. Reimund Neugebauer Prof. Dr.-Ing. Dieter Weidlich Reichenhainer Strae 70, 09107 Chemnitz, Germany Tel.: +49(0)0371 531-23500 Fax: +49(0)0371 531-23509 Email: wzm@mb.tu-chemnitz.de Internet: www.tu-chemnitz.de/mb/WerkzMasch

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Contents: 1 1.1 1.2 1.2.1 1.3 1.4 1.5 2 2.1 2.2 2.3 2.3.1 2.3.2 2.3.3 2.4 2.4.1 2.4.2 2.4.3 2.5 2.6 2.6.1 3 3.1 3.2 3.3 3.3.1 3.3.2 3.4 3.4.1 3.5 Security ............................................................................................................................ 5 Introduction ...................................................................................................................... 5 Reliability .......................................................................................................................... 6 Technical solution principles ............................................................................................. 7 Pneumatic equipment security ......................................................................................... 8 Hydraulic equipment security ......................................................................................... 10 Electrical equipment security ......................................................................................... 12 Commissioning ............................................................................................................... 14 Introduction .................................................................................................................... 14 General instructions for commissioning ......................................................................... 15 Commissioning of pneumatic equipment ....................................................................... 16 The application of oil-mist lubricators ............................................................................. 16 The implementation of commissioning ........................................................................... 17 Inspection ....................................................................................................................... 18 Commissioning of hydraulic equipment ......................................................................... 19 Filling of a device with hydraulic fluid ............................................................................. 19 The implementation of commissioning ........................................................................... 20 Inspection ....................................................................................................................... 21 Commissioning of electrical equipment .......................................................................... 22 Commissioning of programmable logic controls ............................................................ 23 Typical programming errors ........................................................................................... 23 Troubleshooting .............................................................................................................. 24 Definition ........................................................................................................................ 24 The localization of errors while commissioning .............................................................. 24 The approach of troubleshooting ................................................................................... 25 Troubleshooting using a function diagram ..................................................................... 25 Troubleshooting using troubleshooting programs .......................................................... 25 Frequent commissioning errors ...................................................................................... 27 Using of PLC in troubleshooting ..................................................................................... 27 Troubleshooting while commissioning ............................................................................ 28

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Security, commissioning and troubleshooting

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1
1.1

Security
Introduction
Miscellaneous machines and devices may cause versatile hazards. These hazards may occur in different ways, like for example defective constructional components, missing isolation or tripping hazard, insufficient knowledge concerning hazards, deadline pressure or lack of experience.

Each person, who handles with a machine may be endangered. This includes the assembly operators who install the machine and the commissioning personnel. The machine operators and the service personnel are also exposed to hazards during the normal operation cycle. Because of the fundamental requirement of security for all engaged personnel in general, a wide variety of protection directives was improved. In order to impart these directives, regular briefings and training courses are required. The directives used in Europe have the character of decrees. In Germany for example, the European machinery directive is converted by law to the equipment security decree. The directives are supported with security standards. These standards contain solution proposals for machinery construction considering different security aspects. The European security standards are classified in a three-stage system. A-standards are the fundamental security standards. They determine the fundamental concepts and the general organizational principles for machines. The risk evaluation is also included here. B1-standards include for example safety margins, protection equipment or gripper speeds B2-standards contain directives for technical protection equipment. This includes locking equipment and also two-hand and emergency stop circuits. C-standards are machinery typical. This includes standards for mechanical or hydraulic presses, mechanical press brakes or industrial robotics. The C-standards have a priority over A and B-standards. They also remain in force in case of discrepancy between the single standards. However, the CE mark of the EC machinery directive for example, can be issued only when all A, B and C-standards are fulfilled.

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1.2

Reliability
The security of a machine or device is determined by the presence of safety measures, that prevent or reduce the possible consequences or aftereffects for operating personnel and environment. On the other hand, the reliability designates the ability to perform a certain function. Therefore, a reliable function is not necessarily a secure one. The required reliability determines the constructive design of a system. This may be for example the requirement of reserve elements. The maintenance and servicing should be also respectively planned. Example The contacts of a relay are designed for a certain electrical current and voltage. They frequently have a life time of several millions of cycles. After the life time is attained the relays must be replaced. The replacement is indispensable for relays with security related functions. In order to determine the reliability and the security of a system, different reliability parameters are used. Here, the states operable and inoperable are used. The following reliability parameters are used for systems, which should not be refubrished in the future: failure rate, life time distribution, failure probability, survival probability, failure probability density.

On the other hand, the following reliability parameters are used for systems, which should be refubrished or reconditioned in the future:: average life time until the first failure, mean time between failures, average life time between two failures, average downtime, instantaneous and stationary availability, maintainability.

It is clear, that some separate values are calculated using the mathematical probability calculations.

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1.2.1

Technical solution principles

In the security technics different solution possibilities are used. The following principles clarify this. The principle of function sharing assigns different functional elements to separate functions, that should be performed by a certain constructional component. For example, a pressure tank can be supported with high quality steel inside. This prevents corrosion. The forces caused by pressure inside the tank are absorbed by normal steel. The principle of the secure existence means, that not only each separate element of a constructional group, but the whole group must attain the desired life time without any failure or breakdown. For this, each constructional component is oversized with a certain security factor. The principle of limited failure allows a restricted perturbation, which should not have any severe consequences. The following conditions should be taken into consideration: The expected perturbation may limit the functioning so that no hazard to operating personnel, environment or property is caused. The limited functioning must last as long as the related component is safely stopped and replaced. The malfunction of the defective component must be easily recognizable. In case of failure of a component, the evaluation of the whole security state must be possible. In the principle of multiple assignment several constructional components are arranged so that additional components undertake the complete or at least a part of the functions of defective components. This is also designated as redundancy. The redundancy may be active or passive. In the active redundancy all constructional groups are in use, although the function can be undertaken by one single group. In fact, this causes the reduction of the overall life time, but certainly no functional problems will occur. In the passive redundancy the components assigned for failure situations are kept in reserve. They must be switched on to start functioning. The principle of diversely performed multiple assignment is similar to the redundancy. However, a different activation principle is used with different constructional groups that have the same function. For example, the main pump may be electrically operated, while the reserve pump by means of a combustion engine.

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1.3

Pneumatic equipment security

The DIN EN 983 in particular determines the technical security requirements for fluid-technical equipment and its components. This standard includes the principles and instructions for the design, construction and conformance of constructional components or systems. Furthermore, it includes the instructions and directives for assembly, installation, operation and maintenance. The most important instructions are described in the following. The constructional components of a device may be used and operated exclusively in compliance with the conditions determined by the manufacturer or the supplier. The mechanical motion should not cause any hazards for persons. The effluent air should not cause any danger. The switching on and off of the power, as well as its decrease, failure or restitution should not cause any hazards. Any pressure leakage or decrease to a critical value should not endanger the personnel. The design and construction of the devices should allow access to all constructional components and guarantee their secure installation and maintenance possibility. The protection equipment must guarantee that the specific parameter values of a device can not be exceeded. For example, the maximal operational pressure in the pneumatics is restrained by means of safety valves. Pneumatic drives, such as cylinders or motors are assigned for certain uses according to their construction. The parameters of pressure, torques or rotational frequencies, fixation and connections determined by the manufacturer should be followed and kept. Notice that the drives have a construction that allows to carry any expected forces. The related information can be found in the catalogues and operation manuals. Concerning the pneumatic cylinders the following should be attended to in particular: the buckling security, the stroke end impacts, the alignment and fastening and the piston rod protection.

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At the construction period of pneumatic valves some points should be already taken into consideration. This includes the valve type and the construction type, the installation position and the fastening. Furthermore, the valves operation type and the supporting hand operation in electrically operated valves should be also attended to. The valves should be indicated according to the equipment indication rules. The used lubricants must be compatible with all constructional components, synthetic materials, sealings, tubes and pipes. Here, the manufacturers recommendations should be taken into consideration. Nowadays, many valves have a lifetime lubrication, which suffice for the whole life time. In this case, the enrichment of the compressed air with oil mist is not required or even destructive. Once lubricated with oil mist, the valves require a further regular oil mist lubrication. The compressed air pipes should be arranged so that the possibility of their use for purposes other than intended, as stepladders for example, is prevented. Incorrect connections should be prevented, because this may cause hazards. The pipes and pipe connections should not affect the operational process. The accessibility needed for installation works, maintenance or replacement of constructional groups should not be affected in any case. Canals, pipes and pipe connections must be kept free of foreign bodies. The pipes should be securely fixed at their ends. Here, the fixations should not be welded on the pipes. In general, the fixations should not cause damage to pipelines. It is prevented to use pipelines for the fastening of devices. In the pneumatics, some pipelines can be made of synthetic materials. The technical characteristics of these pipes should be attended to. The regulations of the DIN EN 286-1 are used for the compressed air tanks. They should be positioned possibly in cool locations. A sufficient accessibility to the tanks is required. An anti-corrosion finishing is required for compressed air tanks. This is important for aggressive environment types in particular. On the other hand, the compressed air may contain water. Filtering and drainage equipment must be placed in suitable locations. Non-metal tanks should be supported with crash rings.

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1.4

Hydraulic equipment security

The DIN EN 982 determines the technical security requirements for hydraulic equipment. This standard includes the principles and instructions for the design, construction and conformance of constructional components or systems. Furthermore, it includes the instructions and directives for assembly, installation, operation and maintenance. The most important instructions are described in the following. The constructional components of a device may be used and operated exclusively in compliance with the conditions determined by the manufacturer or the supplier. The mechanical motion should not cause any hazards for persons. All constructional components should be protected from pressures, that exceed the maximal operational pressure. This is usually performed by means of pressure control valves. The pressure impacts should be limited to a minimal value. This should be already taken into consideration in the design, construction and installation stages of the device. In general, possible pressure impacts should not cause any hazards. The switching on and off of the power, as well as its decrese, failure or restitution should not cause any hazards. Any pressure leakage or decrease to a critical value should not endanger the personnel. Any internal leakage inside the constructional components should not cause any danger. The design and construction of the devices should allow good accessibility for installation works, maintenance or replacement of constructional groups. The following conditions should be in particular attended to during the design and construction stages: possible swingings, high or low temperatures, intensive fouling and fire or explosion hazards. Furthermore, any unnecessary heat formation should be prevented. The full range of operational temperature values should be specified. The temperature of the pressure medium should not exceed the allowed value. Pipes and tubes should not disturb the installation and maintenance works. Their dismounting during a maintenance should not cause high losses in the hydraulic fluid. A discharging of the tank should not be necessary as well.

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