Case Studies of Comparing EN 954-1 and EN ISO 13849-1 Standard for Design of Industrial Machinery Safety Control System

Tae-Ho Kim,Hong-Ki Kim,Hoon Yong Yoon 대한인간공학회 2013 대한인간공학회지 Vol.32 No.3

Objective: The aim of this study was to compare old standard EN 954-1 and new standard EN ISO 13849-1 through case study and provide necessity of adaptation of EN ISO 13849-1 in Korea. Background: International and EU harmonized standard EN ISO 13849 "safety of machinery - Safety-related parts of control system" is classified into Part 1: General principles for design and Part 2: Validation. EN ISO 13849-1 standard was introduced in Official Journal of the European Union on September 8, 2009 as harmonized standard, and old standard EN 954-1 was withdrawn on December 31, 2011. So, EU decided to use of EN ISO 13849-1 standard forcibly from January 1, 2012 for safety of machinery. New machines need to be CE marked if they are to be placed on the market in the European Economic Area(EEA), Switzerland or Turkey, and Korean machine builder should apply EN ISO 3849-1 standard for safety of machinery accordingly. However, current Korean Safety Certification system(KCs mark) for dangerous machinery is not referred to EN ISO 13849-1 standard as safety standard. There is a need of research for adaptation of EN ISO 13849-1 standard in Korea as safety standards for new design of safety-related control system which use mostly electronic components. Method: Five case studies of representative designs for safety-related control system in accordance with EN 954-1were selected according to safety category from B to 4. And these five representative designs were tried to change new design in accordance with EN ISO 13849-1 standard. The results of comparison were analyzed in aspect of economy and technical complexity. Results: The results showed that EN ISO 13849-1 provided quantitative method of application and it enabled designers to create safety-related control systems that require fewer components and less wiring, with many of the components being to a lower specification and, therefore, less costly. Conclusion: EN ISO 13849-1 standard is good for electronic safety-related control systems compare to EN 954-1. By considering the importance of application of EN ISO 13849-1 and benefits, the application of EN ISO 13849-1 as safety standard for safety of machinery is urgent in Korea. Application: The results of comparing EN 954-1 and EN ISO 13849-1 standard might help to determine the adaptation of EN ISO 13849-1 standard for safety of industrial machinery in Korea.

EU 기계류 안전 지침(Machinery Directive 2006/42/EC)에 따른 기능 안전 설계/검증/평가 및 적합성 입증 방법론에 관한 문헌적 고찰- 토공기계 및 지게차 분야의 국제 표준 개발 동향을 중심으로 -

백종희 표준인증안전학회 2019 표준인증안전학회지 Vol.9 No.2

EU Machinery Directive 2006/42/EC, which is a representative safety regulation in the states of European Union, provides not only primary safety principle such as safety for fire and explosion, emergency stop, guard installation, FOPS, ROPS, TOPS, etc., but also functional safety related with hardware/software fault prevention, etc. On the other hand, in accordance with ISO/IEC Guide 51, standards for safety is categorized as A-type, B-type and C-type. Among the EU member states, these kinds of standards are adapted as European Standards and utilized as a reference to Conformity Assessment for the machinery manufacturers. Therefore, in this study, We will study the necessity of adaptation of functional safety design/ verification/validation process in accordance with EU Machinery Safety regulation and ISO 12100, ISO 13849, etc. We will also review the necessity of korean manufacturers’ self declaration of conformity with regards to the newly developed standard in ISO/TC 127 Earth-moving machinery and in ISO/TC 110 Industrial trucks such as fork-lift trucks for material handling. In addition, We will provide briefly, as a reference, the current C-type standard development status for determining Performance Level(PL) of wheel loaders, excavators and industrial trucks for material handling in order to obtain korean manufacturers’ technical capability for product development and mass production in accordance with functional safety design/verification/ validation process. 유럽 연합(EU)의 대표적 안전 규제인 기계류 안전 지침(Machinery Directive)에서는 화재․폭발, 비상 정지, 가드 설치, 전도․전복 방지 등의 일반 안전과 함께 하드웨어/소프트웨어 결함․오류 방지 등 기능 안전에 대한 대응책 마련을 규정하고 있다. 한편, ISO/IEC Guide 51에서는 안전 관련 국제 표준을 A∼C-type으로 구분하고 있으며, EU에서는 해당 표준을 유럽 지역 표준(EN 등)으로 부합화하고 관보에 게재함으로써 기계류 안전 지침에 대한 적합성을 입증할 수 있는 기준으로 활용하고 있다. 따라서 본 연구에서는 기계류 안전 지침과 ISO 12100 및 ISO 13849 등을 연계한 기계류의 기능 안전 설계/검증/평가 체계, 그리고 토공기계(ISO/TC 127) 및 지게차(ISO/TC 110) 분야의 최근 국제 표준 개발 동향을 중심으로 제조자 자기 적합성 선언 등에 관한 법령과 표준 관련 문헌의 검토․분석을 통해 국내 건설기계 산업계의 기능 안전 설계/검증/평가 대응 필요성에 대하여 고찰하고자 한다.

기능 안전 설계 목표 PLc∼PLd를 갖는 이동식 기계류의 소프트웨어 개발에 요구되는 대표적 시험 평가 항목의 도출 - 건설기계 및 농기계 분야의 국제 표준 비교․분석을 중심으로 -

백종희(Baek, JongHee) 표준인증안전학회 2021 표준인증안전학회지 Vol.11 No.2

유럽 연합(EU)의 대표적 안전 규제인 기계류 안전 지침(Machinery Directive)에서는 화재․폭발, 비상 정지, 가드 설치, 전도․전복 방지 등의 일반 안전과 함께 하드웨어/소프트웨어 결함․오류 방지 등 기능 안전에대한 대응책 마련을 규정하고 있으며, 이동식 기계류인 지게차, 굴착기, 로더와 같은 토공 기계 및 트랙터 등 농기계에 대해서는 B-type 안전 표준인 ISO 13849-1:2015의 4.6.2절, C-type 안전 표준인 ISO 19014-4:2020 및 ISO 25119-3:2018의 7절 등에서 기계류 안전 지침에 따른 개발 제품 적합성 입증을 위한 S/W 설계/개발및 시험 방법론을 제시하고 있다. 본 논문에서는 첫째로 기계류 안전 지침과 ISO 13849, ISO 19014 및 ISO 25119 등을 연계한 이동식 기계류의 기능 안전 설계/검증/평가 체계와 지게차, 토공기계 및 농기계의 기능 안전 설계 적용 S/W 개발 및 시험방법론의 주요 특징을 비교․검토하고 국내 건설기계 및 농기계 산업계의 대응 필요성에 대하여 고찰하고자 한다. 둘째로 기능 안전 프로세스에 따라서 설계 목표 PLc 또는 PLd를 갖는 기능 안전 설계 적용 대상 부품에 대하여 개념 설계 단계에서 요구될 수 있는 소프트웨어 설계/개발에 대한 대표적 시험 평가 항목의 도출 사례를 간략하게 소개하고자 한다. 결과론적으로, 건설기계 및 농기계와 관련된 B-type, C-type 국제 표준의 비교․검토를 통해 설계 목표 PLc 또는 PLd를 갖는 소프트웨어 기능 안전 설계/평가의 주요 평가 항목을 정적 분석(static analysis) 또는 동적시험(white box-test 또는 black-box test)으로 구분하여 도출하였다. EU Machinery Directive 2006/42/EC, which is a representative safety regulation in the states of European Union, provides not only primary safety principle such as safety for fire and explosion, emergency stop, guard installation, FOPS, ROPS, TOPS, etc., but also functional safety related with hardware/software fault prevention, etc. In addition, for fork-lift industrial trucks, earth-moving machinery and agricultural machinery, which are all belongs to representative mobile machinery, software design/development and testing methods are provided at ISO 13849-1:2015, ISO 19014-4:2020 and ISO 25119-3:2018. Therefore, in this study, We will compare and review the key features of software development and test methods for applying functional safety designs for mobile machinery with the European Directive and standards such as ISO 13849, ISO 19104 and ISO 25119. In addition, for the purpose of applying functional safety designs in mobile machinery, we would like to briefly introduce the sample case of software design/development and test validation process that may be requested during the conceptual design phase for the SRP/CS belongs to performance level between PLc and PLd.

ISO 13849-1 기반 건설현장 세륜기용 안전차단 제어시스템(SRP/CS)의 성능수준 산정 및 검증에 관한 연구

김성환,주용한 한국설비안전학회 2025 한국설비안전학회지 Vol.30 No.4

This study aims to establish a functional safety design and verification framework for construction-site wheel-washing systems in accordance with the ISO 13849 standard. The target system, composed of a high-pressure pump, automatic gate, sensors, and a PLC controller, was modeled as a Safety-Related Part of a Control System (SRP/CS). A risk assessment based on ISO 12100 was performed to derive the required performance level (PLr) for each safety function, and the achieved performance level (PLcalc) was evaluated using the SISTEMA tool. The SRP/CS was designed using Category 2–3 architectures, with key parameters—MTTFd, DCavg, and CCF— assessed following ISO 13849-1 guidelines. Validation testing demonstrated that all safety functions satisfied the condition PLcalc ≥ PLr (SF1 = d, SF2 = c, SF3 = b) and achieved an average system response time of less than 1.0 s. These results confirm that the proposed SRP/CS configuration ensures reliable functional safety performance and can serve as a practical reference model for safety evaluation of similar industrial equipment.

사례 연구 : EN ISO 13849-1의 안전회로 설계를 위한 구체적 평가 기준의 적용

정환석,이동주 한국산업경영시스템학회 2018 한국산업경영시스템학회지 Vol.41 No.1

With the development of industrial technology and science, production and manufacturing facilities have been enhanced and improved, and the importance of the safety of workers has also been regulated and limited by various safety management methods. As a way to secure the safety of the workers from the production facility, the fail-safe and fool-proof methods are now being applied. Any possible insecure behavior and unsafe conditions can be removed by adopting the standards and specifications that are now secure the safety of workers and equipment. This research analyzes EN ISO 13849-1 international and European standards during CE certification. In order to secure acceptable reduced risks, the risk assessment process of ISO 12100 and the processes for reducing its risk are applied. In the current ISO 13849-1 standard, the criteria for the required performance level PLr (Required Performance Level) for the applicable risk and safety functions through the risk assessment are subjective and not subdivided. Therefore, the evaluation criteria are likely to cause judge’s judgement error due to qualitative judgement. This research focuses on evaluation and acceptable performance level setting for the safety circuit of the equipment. We propose an objective and specific evaluation criteria to secure safety, and the proposed evaluation criteria are applied to the case study of the safety circuit for the equipment. In order to secure the safety of the entire safety circuit, the improvement of the MTTFd and DC level related to the SRP/CS (Safety-Related Parts of Control Systems)’ lifetime is required for the future research.

건설기계 기능안전의 실무적 접근 및 표준화 동향

엄정규(J. K. Um),김광석(G. S. Kim),이선호(S. H. Lee),오기쁨(K. P. Oh) 유공압건설기계학회 2020 유공압건설기계학회 학술대회논문집 Vol.2020 No.12

Functional safety is part of the safety related with E/E/PE safety related system and it must be achieved only when the safety control system is operated normally as intended demand. In addition, To achieve the functional safety, it need to high level of reliability and safety of the required safety control system. Recently, The importance of functional safety of E/E/PE system is getting growing. Thus, In this paper, we analysis ISO 13849-part 1 and ISO 19014 series standards that are one of the functional safety standards. And we describe functional safety design method according to these standards so that these standards can be applied Machinery and Earth Moving Machinery.

ISO 13849-1 기반 엔진제어시스템 개발 방법론

최원준(Wonjun Choi),신태범(Taebeom Shin),나종성(Jongseong Na) 한국자동차공학회 2013 한국자동차공학회 학술대회 및 전시회 Vol.2013 No.11

엔진제어시스템 기능안전을 위한 소프트웨어 강건 설계

최원준(Wonjun Choi),신태범(Taebeom Shin),나종성(Jongseong Na) 한국자동차공학회 2013 한국자동차공학회 학술대회 및 전시회 Vol.2013 No.11

산업용 로봇 셀 안전기능 제어시스템 성능수준 연구

이중남,이동호 한국안전학회 2023 한국안전학회지 Vol.38 No.3

Most existing industrial robots have fences installed around them to ensure safety. However, industrial sites are recently being transformed into workspaces shared by both robots and humans working cooperatively, wherein the robots are without security fencing owing to the development of sensor technology. However, in the last five years (2017–2021), 16 deaths have occurred due to robots at industrial sites, with the main cause of the accidents being workers approaching an industrial robot in operation and getting entangled with or colliding into the robot and its peripherals. To prevent such accidents, multilateral research is needed. To this end, this study analyzes the nonconforming contents of safety inspections for industrial robots and demonstrates the safety performance of the safety function control system implemented in an industrial robot cell. In addition, to ensure the fundamental safety of industrial robots, this study proposes the introduction of a safety certification system so that safety functions can be implemented in the design, manufacturing, and installation stages of the robots.

건설장비 제어시스템 기능안전

윤재학(J.H. Yoon),김성기(S.K. Kim),권영민(Y.M. Kwon) 유공압건설기계학회 2015 유공압건설기계학회 학술대회논문집 Vol.2015 No.6

Recently, the application of electrical and electronic (E/E) control system has been increased in the construction equipment. Thus, the risks caused by systemic failure and potential malfunction of the E/E control system should be considered in design process. The design methods according to the functional safety standards have been recommended to reduce these risks because they could not be removed only by the quality control. This paper described the functional safety design by using design & verification methods based on the development process of ISO 26262, ISO 13849 and ISO 15998. The support process for the functional safety was described by the standard for automobile (ISO 26262) including state-of-the-art methods. The functional safety design methods are expected to improve not only the functional safety but the quality and the reliability of the E/E control systems as well.