OUR APPROACH

Ergonomic Design 

We design automation systems that put people first—boosting safety, comfort, and productivity on the factory floor. 

  • Ergonomic Workstations: Adjustable heights and optimized reach zones. 
  • Smart Interfaces: Easy-to-use HMIs with clear visuals and intuitive controls. 
  • User-Friendly Design: Machines and processes designed for comfort and ease of use. 

Machinery Safety

Industrial automation machinery safety focuses on preventing accidents and injuries associated with automated equipment in manufacturing and other industrial settings. It involves a multi-faceted approach including risk assessment, implementation of safety measures like safeguarding devices and safety-related control systems, proper training, and regular maintenance. 

Black Controls utilizes (GAMP) Good Automated Manufacturing Practice, and executes the following measures when integrating industrial automated machines:

1. Risk Assessments

  • Identifying potential hazards associated with automated machinery, including mechanical, electrical, and other hazards.
  • Evaluating the likelihood and severity of potential harm to workers.
  • Understanding the specific hazards associated with each piece of equipment and the overall automated system.
  • Performance Level (PL) refers to the value that indicates the capability of safety-related parts of control systems to carry out a safety function under foreseeable conditions.

2. Safeguarding Measures

  • Fixed Barriers: Physical barriers like fences or enclosures to prevent access to hazardous areas.
  • Interlocked Barrier Guards: Guards that automatically stop the machine when opened, preventing access to moving parts.
  • Light Curtains and Laser Scanners: Devices that detect obstructions in a defined area and trigger a stop signal.
  • Emergency Stop Devices: Pushbuttons or other controls that immediately halt the machine in an emergency.
  • Robot Safety: 
  • Position Monitoring
  • Speed Control
  • Safe Zones
  • Collision Detection

3. Safety-Related Control Systems

  • Safety Programmable Logic Controllers: Used to monitor safety functions and respond to potential hazards.
  • Emergency Stop Mechanisms: Devices that immediately halt the machine in an emergency.
  • Fail-Safe Protocols: Systems that automatically shut down the machine in the event of a failure. 
  • Redundancy and Diversity: Using multiple safety systems or components to ensure that if one fails, another can still maintain safety. 

4. Training and Procedures

  • TUV NORD accredited PILZ CMSE – Certified Machinery Safety Experts on staff
  • Safe Work Procedures: Developing and implementing clear procedures for operating and maintaining automated systems.

5. Standards and Regulations

  • CSA Z432-Safeguarding of Machinery
  • CSA Z434-Industrial Robots and Robot Systems
  • CSA Z462-Workplace Electrical Safety
  • ISO 13849-1: Focused on the safety-related parts of control systems (SRP/CS) and Performance Level (PL).
  • ISO 12100: Provides guidelines for the general principles of machinery safety.
  • ANSI B11.0: Addresses safety of machinery for the metal and woodworking industries.
  • OSHA Regulations: Provide guidelines and regulations for workplace safety in the United States.
  • Machinery Directive (EU): A set of directives governing machinery safety in the European Union.

Serviceability  

Our automation systems are designed for easy maintenance and quick repairs, with easy access to components, ensuring minimal downtime and easy repairs.

  • Modular Components for quick replacements and upgrades. 
  • Easy Access Points for fast repairs and maintenance. 
  • Clear Error Alerts/Faults for simple troubleshooting. 
  • Predictive Maintenance to reduce unplanned downtime.