Perimetra functional safety for upgrading an injection moulding line for thermoplastic moulds

Industria Bergamasca Mobili S.p.A. , ISO 9001 and ISO TS16949 certified, works in the field of injection moulding of plastic materials and employs advanced technologies both in its moulding process (for example with RHCM) and in the automation of the production lines.

Accessafe has been commissioned to develop a safety plan for nine injection molding machines used for thermoplastic molds, including the associated unloading automation.

After reviewing the risk analysis prepared by the client and the Essential Safety Requirements (ESRs), Accessafe’s technicians developed the safety system layout in accordance with harmonized standards, including the access control design based on the PLr (Performance Level) determined in accordance with the relevant UNI EN ISO 13849:2016 standard.

In just three weeks from the date the technical specifications were approved, Accessafe delivered the complete turnkey project:

Material

Penta Guard Fencing System, 20 x 100 mm mesh ,2520 mm height combined with Meta 1 Fixing Brackets 60×60 mm section
N.1 controlled access by means of a FG60 sensor in the Clo.Sys lock combined with a FR992 micro-switch in order to achieve PLd.

Mechanical component assembly

Assembly of guard fencing panels and access control system

Laying and cabling of implemented parts

Wire and cable sleeving, sensor connection and interfacing
Control Electrical Cabinet
N.1 signal light

Functional tests and documentation release

Upon installation termination, functional tests were carried out in the presence of plant manufacturer and BM SpA operators in order to release the following documentation:

Certification
User and Maintenance Manuals
Technical Data Sheets and Electrical layouts

The above mentioned documentation was essential for the plant user to achieve CE marking for the complete line.

Injection moulding machine line access project for thermoplastic moulds — *Electro-locking system with access request management*

Accessafe line of injection molding machines for thermoplastic molds — *Falling parts prevention protection system in operator area*

Executive design of the system

In-depth analysis by Marco Vaccarone CMSE® Certified Machinery Safety Expert follows below

“This project needed use to fence-off an automatic manipulator acting as a vacuum Pick-and-Place device at low speed, due to product fragility, of 250 mm/sec and 5 pcs/hour.

Such features allowed us to manage part-exit opening on a conveyor belt and as residual risk apply dedicated notices (92/58/CEE Directive) which would inform operators about the eventual risks of mounting the belt. By doing so we delivered a safe solution without having to apply photo-electric barriers.”