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FUNCTIONAL SAFETY SYSTEM DESIGN

Ensuring that systems operate safely and reliably, particularly where failure could lead to harm or danger.

Our certified Functional Safety Engineers provide safety system design in accordance with IEC 61508:2010 Functional Safety Of Electrical/Electronic/Programmable Electronic Safety-Related Systems, IEC 62061:2021 Safety integrity level, and ISO 13849:2015 Safety of machinery – Safety-related parts of control systems.

Safety system design is an integral feature of all our systems. 

We also provide outsourced consultancy to advise on or validate third-party designs.

Desk Safety Console

Functional Safety System Design

Functional safety system design refers to the process of designing systems and devices to ensure that they operate safely and reliably, particularly in situations where failure could lead to harm or danger. It is commonly applied in industries such as automotive, aerospace, healthcare, and manufacturing, where the consequences of system failures can be severe.

Design and Implementation

Safety-Schematics

Design

Critical safety circuit design

BwSafety-Code

Software

Software programming

Safety Cabinet

Hardware

Bespoke hardware design & build
Control Desk

Control

Control architecture and infrastructure
Integration Patch Panel

Integration

Test system and cell integration

​Rigorous System Development

Key elements of functional safety system design include:

Risk Assessment:
The first step is to identify and assess potential risks associated with the system. This involves analysing how failures could impact safety, the likelihood of such failures, and the severity of their consequences.

Hazard Analysis:
This involves identifying potential hazards and assessing the risks associated with a system or process. Common methods include Hazard and Operability Studies (HAZOP), Fault Tree Analysis (FTA), and Failure Modes and Effects Analysis (FMEA).

Safety Requirements Specification:
Defining clear safety goals and requirements for the system, which are often specified in terms of specific safety performance levels (SIL – Safety Integrity Level, or ASIL – Automotive Safety Integrity Level).

Safety Architecture:
Design the system’s architecture with redundancy and diversity to ensure that even if a component fails or an error occurs, the system can still operate safely. This may involve using redundant sensors, actuators, or processing units.

Functional Safety Measures:
Implement safety mechanisms, such as safety interlocks, alarms, and shutdown procedures, to maintain safe system operation. These measures should detect and react to faults or failures.

Safety Verification and Validation:
We thoroughly test the system to ensure it complies with safety requirements. This includes hardware testing, software verification, and validation against the established safety goals.

Safety Documentation:
We provide detailed documentation of the system’s design, risk assessments, testing procedures, and other relevant information. This documentation is often required for compliance and safety certification.

Functional Safety Standards:
We adhere to relevant functional safety standards specific to the application, including IEC 61508:2010 Functional Safety Of Electrical/Electronic/Programmable Electronic Safety-Related Systems, IEC 62061:2021 Safety integrity level, and ISO 13849:2015 Safety of Machinery — Safety-related parts of control systems, which provide guidelines and best practices for functional safety.

Functional Safety Lifecycle:
We follow a structured safety lifecycle, which typically includes phases like concept, design, implementation, testing, and operation, with safety considerations integrated at each step.

Change Management:
Establishing procedures for managing changes to the system throughout its lifecycle, ensuring that modifications do not compromise safety.

Continuous Improvement:
Establish a process for ongoing monitoring and assessment of the system’s safety performance. Periodic safety assessments and audits help identify and address potential issues.

Maintenance and Monitoring:
Developing plans for ongoing monitoring and maintenance to ensure the system’s continued safety and reliability.

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