24 Rockwell Automation Publication IASIMP-QS005H-EN-P - April 2016
Chapter 1 Risk Assessment and System Design
Panel Assembly Feed Conveyor (B)
Analysis of the Panel Assembly Feed Conveyor (B) yields the following information.
Part weight: 12 lbs
Indexing frequency: 8…12 parts per minute
Drive: 3 HP PowerFlex® 70 Variable Frequency Drive, 460V, 3-phase
Two mechanical brakes: power to release, spring to hold (fail to safe)
Top speed: 12 in./s (30 cm/s)
Tested stop time: 0.3 s
Index time: 2…3 s
Pneumatic clamp actuator: pneumatic cylinder, 80 psi (5.6 kg/cm) required
Top speed: 32 in./s (81 cm/s)
Tested stop time: 0.35 s
Task: The operator realigns parts in the part locators at Positioning Station #1 and Positioning Station #2 of the Panel
Assembly Feed Conveyor. Maintenance personnel adjust tool positioning at both stations and lubricate and repair
equipment as needed.
The Panel Assembly Feed Conveyor has sensors to indicate when a part is in position at Positioning Station #1 for rough
alignment and at Positioning Station #2 for final alignment and part holding for assembly. A stack light annunciates
proper part positioning with a green light and improper loading with a red light.
The Panel Assembly Feed Conveyor is loaded automatically upstream of this station.
Table 5 - Proposed Architecture for Panel Assembly Feed Conveyor
Components Standard Inputs Safety Inputs Safety Outputs Comments
Drive enable 1 The standard input is the output of the control system into
the safety logic to initiate the drive motion.
Safety enable 1 1 Enable to the PowerFlex 70 Drive
Safety enable 2 1 Enable to the PowerFlex 70 Drive
Feedback 1 1 Drive Safety System Feed Back #1
Feedback 2 1 (Feedback can be wired in series)
Pneumatic safety valve #1 1 …
Pneumatic safety valve #2 1 …
Pneumatic safety valve feedback 1 …
Total: 12 or 34
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