Machine Safety, SIL & Performance Level Audits
Ensuring operator safety and regulatory compliance. Expert ISO 13849 / IEC 62061 audits, SISTEMA probability modeling, safety circuit integration, and stop-time testing.
SISTEMA Modeling & Stop-Time Validation Pipeline
Rigorous functional safety architecture engineered to achieve certified Performance Level e (PL e) / SIL 3 compliance.
Machine Safety Specializations
Professional functional safety auditing and verification services engineered to protect personnel and ensure full regulatory compliance.
ISO 12100 Hazard Identification & Risk Assessment
Comprehensive evaluation of machinery pinch points, kinetic energy hazards, and operational risks to establish required safety performance levels.
SISTEMA Functional Safety Architecture Design
Evaluating safety-related control systems (SRCS) using SISTEMA software to mathematically verify achieved Performance Levels (PL a-e) and SIL ratings.
Emergency Stop, Light Curtain & Guard Locking
Integrating dual-channel safety relays, safety PLCs, optical light curtains, RFID safety switches, and dynamic guard-locking mechanisms.
Machine Coast-Down & Stop Time Testing
Executing precision stop-time measurements to calculate safe safety-distance boundaries for optical light curtains and pressure-sensitive safety mats.
Machine Safety Engineering Parameters
| Safety Parameter | Engineering Scope & Deliverables | Governing Standard |
|---|---|---|
| Safety Standards | ISO 13849-1/2, IEC 62061, IEC 61508, ISO 12100, OSHA / CE Guidelines | ISO / IEC International |
| Safety Controllers | Pilz PNOZmulti, Siemens S7-1500F / ET 200SP F, Sick Flexi Soft | IEC 61508 SIL3 / PL e |
| Sensing Devices | Sick/Keyence light curtains, Euchner RFID interlocks, emergency stop pushbuttons | ISO 14119 / ISO 13850 |
| Calculation Tools | SISTEMA (Safety Integrity Software by IFA) for probabilistic architecture modeling | ISO 13849-1 Annex D |
| Enclosures & Wiring | Dedicated yellow safety enclosures, monitored dual-channel feedback wiring | IEC 60204-1 Electrical |
4-Step Machine Safety Audit & Deployment
Hazard & Risk Audit
Inspecting machinery mechanical, hydraulic, and electrical systems to catalog hazards and determine required risk reduction.
Architecture & SISTEMA Modeling
Designing safety control circuits and executing SISTEMA calculations to verify MTTFd, DCavg, and CCF parameters.
Physical Integration & Wiring
Installing safety relays, redundant contactors, emergency stop chains, and tamper-resistant interlock switches.
Validation & Certification
Conducting stop-time measurements, functional testing of fault reactions, and issuing formal compliance validation reports.
Machine Safety & SIL FAQs
What is the difference between Performance Level (PL) and Safety Integrity Level (SIL)?
Performance Level (PL a to e), defined under ISO 13849-1, evaluates safety functions based on machine risk, category, component reliability, and diagnostic coverage. Safety Integrity Level (SIL 1 to 3), defined under IEC 62061 / IEC 61508, uses a similar probabilistic approach but is tailored toward electrical, electronic, and programmable safety-related systems.
Why is machine stop-time measurement critical when installing light curtains?
A light curtain must be mounted far enough away from the hazard so that a person cannot reach the danger zone before the machine comes to a complete stop. Stop-time measurements determine the exact coast-down time of the machinery under load, ensuring the minimum safe distance calculation is mathematically compliant.
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