Functional safety in mechanical engineering is of crucial importance to ensure the safe operation of machines and systems. It ensures that machines react safely in the event of a fault and minimize risks to people and the environment. The definition of functional safety includes all measures that reduce the risk of accidents on machines (e.g. due to malfunctions).
In the area of functional safety it is important (and necessary) to develop preventive strategies to identify potential risks at an early stage. In order to make risk prevention strategies more efficient, functional safety in the drive plays an equally central role, as it directly influences the performance and efficiency of drive systems.
Through the intelligent implementation of comprehensive safety concepts, you not only ensure the protection of people, but also increase competitiveness through increased reliability and reduced downtimes. Functional safety is therefore a strategic success factor in mechanical engineering.
Legal framework: From the machinery directive to manufacturer liability
The EU Machinery Directive (and the forthcoming Machinery Regulation) forms the foundation for safe machinery and therefore also for functional safety. It defines requirements for the design, commissioning and CE marking of machinery. Articles 5 (placing on the market), 7 (presumption of conformity), 12-14 (conformity assessment, CE marking, notified bodies) and 16 (CE marking itself) are particularly relevant.
Manufacturers of machinery bear the responsibility – from the personal liability of the management to the criminal relevance of infringements. The so-called "manufacturer's liability by accident" is also addressed: Anyone who significantly modifies machines can be legally considered a manufacturer.
Practical implementation: risk assessment and technical measures
1. Inherently safe design
Inherently safe design has the highest priority when it comes to minimizing risk. This means that machines are designed in such a way that risks do not arise in the first place. For example, heat generation can be reduced by selecting suitable components in order to avoid the risk of burns. Or an alternative design can be used to eliminate crushing hazards.
2. Technical protective measures
If risks cannot be eliminated by design, technical protective measures are used. These include protective devices such as light barriers, safety fences or door monitoring switches that automatically switch off the machine in the event of danger. Limiting the maximum speed during set-up is also a typical measure. These protective systems must be designed in such a way that they function reliably and cannot be bypassed.
3. Documentation of residual risks
Not all risks can be eliminated completely. These so-called residual risks must be clearly documented – usually in the operating instructions. Especially during transportation, installation and commissioning, there are many scenarios that can only be safeguarded against with precise documentation. The documentation not only serves to provide information, but also to legally safeguard the manufacturer.
Practical examples from our white paper
Safe drive with adjustable maximum speed: The machine manufacturer specifies the maximum speed, which is precisely set by the drive manufacturer's service technician. An acceptance report documents this process.
Control cabinet engineering by third parties: The machine manufacturer defines the safety functions and their quality requirements. The control cabinet manufacturer must implement these requirements correctly through his quality assurance system. A clear delineation of responsibilities is essential here.
External advice on conformity to standards: Even if an external consultant is called in, the responsibility remains with the machine manufacturer. The results of the risk assessment must be taken into account and, if necessary, implemented beyond the requirements of the C standards.
Why act now?
The introduction of the new Machinery Directive, which will replace the previous directive, will result in further detailed requirements for functional safety. Companies that address these requirements at an early stage will not only benefit from legal protection. They also position themselves as responsible and future-oriented partners on the market.
Our white papers on the Machinery Directive and Machinery Regulation will help you with this. Download now