Packaging Company Chooses Pilz Safety Products

Products from Pilz Automation Technology have helped BVM Brunner, a manufacturer of film-wrapping packaging machines, to meet customer requirements while ensuring the safety of machine operators. Pilz specialises in machinery safety solutions, including control and automation products as well as training, engineering and consultancy services. Many of these products and services are suitable for packaging machinery, from small, relatively simple machines to larger, more complex packaging lines and palletising stations.

Having taken an early decision to comply with EN ISO 13849-1, BVM Brunner carried out renewed machine risk assessments in order to update the safety concepts on its machines. Following this, the company decided to implement a new safety design for one of its machines, which incorporated comprehensive safety solutions from Pilz. BVM Brunner's latest machine, the Compacta Genius Servo, is a fully automated machine with a continuous-motion, cross-sealing jaw. A safety solution was required for this machine that would not only safeguard the operator but also complement the flexibility and easy handling required for processing a variety of products.

The Pilz Safety Calculator, or Pascal, was used to determine the required PL/SIL of the safety functions according to EN ISO 13849-1. The PL and SIL requirements, together with the handling requirements, were then matched with the Pilz product range within the Pascal calculator library. The new compact configurable safety relay, the Pnozmulti Mini, was selected to monitor safety functions. Despite its compact 45mm width, the system - with its 20 safe inputs and four safe semiconductor outputs (to SIL 3, PL e) - covered all the safety functions of the machine, including E-Stop, Light Barriers and Safety Gates.

The PC-based drag-and-drop Pnozmulti Configurator also minimised initial setup and enabled individual configuration for different customers and products. The mechanical safety gate switches were replaced with low-maintenance, non-contact magnetic safety switches, Psenmag, which offered high tolerances for setup and switching distance, a visible status indicator and reduced engineering time thanks to plug-in cables. Regardless of the size and complexity of packaging machines, there will often be a need for other safety-related components.

Pilz offers a range of products, including safety switches, safety bolts, optoelectronic safety devices (light curtains), camera-based safety systems and emergency-stop switches. In order to maximise the productivity of packaging machines, high-quality diagnostics are needed. Not only does the company offer a variety of operator displays that can convey relevant information to operators and maintenance engineers, but its PVIS 'intelligent diagnostics' technology provides plain-text messages with precise information on the location of the fault, clearly defined responsibilities and an integrated 'root-cause' display. This ensures that production can be restarted quickly, minimising downtime.

Today, most packaging machines incorporate servo- and motion-control technology. The Pilz Motion Control (PMC) range covers motors, servo drives and motion controllers. The PMCprimo drive, for example, combines the functions of a servo amplifier, a motion controller and a programmable logic controller (PLC) in a single unit - with the added benefit of an integrated safe-stop function. The new PMCprotego offers even more safety functionality, including safe reduced speed, safe operational stop and safe brake test. As well as safety products, Pilz provides machinery safety-related services, including training, engineering and consultancy.

Depending on customer requirements, the company can undertake risk assessments, the SIL determination, engineering design and/or validation of safety-related control systems and CE marking services. Training courses cover both the application of Pilz products and machinery safety standards, regulations and responsibilities, including a C and G-certified machinery safety course.

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