Machine guarding is an essential component of modern machine safety. In industrial production environments, large forces, high speeds, and automated processes are combined daily within complex installations. This creates risks for operators, maintenance technicians, and other personnel working in the vicinity of machinery. A properly designed guarding system prevents access to hazardous areas and reduces the risk of injury caused by moving machine parts, robotic systems, or internal conveyor systems.
Within this context, mechanical reliability plays a crucial role. Machine guarding must not only comply with legal safety requirements, but also withstand the physical loads that may occur in an industrial environment. Examples include collisions with transport equipment, falling objects, or dynamic loads generated by automated systems. If guarding fails under such conditions, this may result in immediate danger to personnel and significant damage to machinery and production processes.
Troax develops machine guarding specifically designed for industrial applications where safety, durability, and structural strength are central requirements. The systems are used in robotic cells, production lines, logistics installations, and automated warehouses, among others. A strong focus is placed on performing impact testing to validate the mechanical performance of the guarding systems under realistic conditions.
Machine guarding forms part of a broader risk reduction strategy as described in international machine safety standards. Within Europe, the Machinery Directive 2006/42/EC provides the legal framework. In addition, standards such as EN ISO 12100 and EN ISO 14120 play an important role in the design and validation of safety guarding systems.
– EN ISO 12100 describes the general principles for risk assessment and risk reduction. It states that risks should be eliminated at the source wherever possible and that physical guarding is a primary measure for preventing access to hazardous areas.
– EN ISO 14120 specifically addresses the requirements for fixed and movable guards. This standard covers mechanical strength, fastening methods, stability, safety distances, and resistance to impact loading. The standard states that guarding systems must be sufficiently robust to withstand foreseeable mechanical loads throughout the entire service life of the installation. This includes not only static loads, but also dynamic impact loads that may occur in industrial environments.
Within machine safety, the focus is often placed on safety switches, interlocks, and safety control systems. Although functional safety is extremely important, mechanical safety remains the fundamental basis of a safe installation. A safety control system may function correctly, but if the guarding fails mechanically, an immediate safety risk still exists.
For this reason, machine guarding must be regarded as a structural safety component capable of withstanding realistic loads throughout the entire service life of the installation.
In industrial environments, various situations may lead to impact loading on a safety fence system. Examples include collisions with forklifts, automated vehicles, pallet systems, or moving machine components. Unintentional mechanical loads may also occur during maintenance activities.
Under such conditions, the guarding must maintain its structural integrity. This means that panels must not detach, fastening points must remain intact, and no hazardous openings may occur that would allow access to hazardous areas.
Particularly in modern automated production environments, the importance of mechanical strength continues to increase. Installations are becoming faster, more dynamic, and more complex, while at the same time higher demands are placed on machine safety and availability. As a result, the demand is growing for guarding systems with demonstrably tested and validated performance.
To determine whether machine guarding can withstand realistic mechanical loads, impact testing is performed. These tests form an essential part of the validation of safety guarding systems and provide insight into system performance under dynamic loading conditions.
During impact testing, collisions are simulated by applying predefined masses and speeds to panels, posts, and fastening components. The objective is to assess how the system responds to forces that may occur during normal operation or incident scenarios.
Troax impact tests are performed in accordance with the test methodology specified in EN ISO 14120:2015. Various factors that determine the safety performance of the system are evaluated.
One important aspect is the structural deformation of the guarding after impact. Although a certain degree of deformation may be acceptable, the safety function of the system must not be compromised. In addition, checks are performed to verify whether fastening components remain intact and whether the guarding continues to prevent personnel from accessing hazardous areas after impact.
The energy absorption capacity of the system also plays an important role. A properly designed guarding system must be capable of absorbing and distributing impact energy without critical components failing. In this regard, not only the panels are important, but also the connections between panels, posts, and fastening systems.
The results of impact testing provide valuable information for further optimization of the design. Potential weak points can be identified and corrected before a product is widely implemented in industrial installations.
A distinctive aspect of Troax impact testing is that the applied test methodology is TÜV-certified. The tests are carried out in the Troax Test Centre, where different machine guarding configurations are subjected to controlled impact loads.
TÜV Rheinland operates worldwide as an independent testing and certification institute for product safety and conformity assessment. TÜV certification means that the applied test methodology has been independently assessed for reliability, reproducibility, and technical accuracy.
According to Troax, the company is the first machine guarding manufacturer whose impact test methodology has been TÜV-certified. This means that not only the final product is evaluated, but also the manner in which the tests are performed.
For machine builders and end users, this provides additional assurance that test results are based on consistent and verifiable procedures. Independent validation is particularly important in safety-critical applications.
Impact test results are often used within technical construction files, CE documentation, and risk assessments. An independently validated test methodology contributes to the reliability of this documentation and supports the substantiation of safety measures within machine designs.
Troax impact tests are aimed at simulating realistic operating conditions. In industrial environments, forces rarely occur statically; in most cases, dynamic loading is involved where speed, mass, and kinetic energy play a role.
For this reason, collisions are simulated during testing that are comparable to situations that may occur in production environments. Not only the panels are subjected to loads, but the complete system is evaluated, including fastening components and supporting structures.
One example is the Smart Fix ST20 impact test, in which a Troax Machine Guard was subjected to an impact load of 134 kilograms at a speed of 20 kilometres per hour. In addition, the Rapid Fix ST30 impact test was carried out using a load of 100 kilograms at the same speed.
These tests provide insight into how different configurations respond to severe dynamic loading conditions.
The purpose of such tests is not solely to demonstrate compliance with standards. Equally important is obtaining insight into the practical performance of the system under conditions that may realistically occur in industrial environments.
The development of machine safety continues to evolve. Industrial automation is changing rapidly due to the rise of robotics, autonomous transport systems, and smart production lines. As a result, the requirements for machine guarding are also increasing.
Where traditional guarding systems were primarily intended to prevent direct contact with moving machine parts, modern systems increasingly need to withstand higher dynamic loads and more complex interactions between humans and machines.
In automated warehouses and logistics systems, autonomous vehicles and conveyor systems can exert significant forces on safety structures. As a result, the demand is increasing for guarding systems with demonstrable mechanical performance.
For this reason, Troax continuously invests in research, product development, and testing procedures.
By developing new fastening systems, stronger constructions, and improved testing methodologies, guarding systems can be adapted to the changing requirements of modern industrial environments.
The combination of standards-compliant design, extensive impact testing, and continuous product development makes it possible to provide safety solutions that meet the technical challenges of modern production installations.
For machine builders, integrators, and end users, demonstrable safety has become increasingly important. Within CE processes and risk assessments, it must be possible to demonstrate that safety measures are effective and comply with relevant standards.
Machine guarding plays an important role in this process because it forms a physical barrier between personnel and hazardous areas.
When the mechanical performance of a guarding system has been demonstrably validated through impact testing, greater certainty is achieved regarding the effectiveness of the selected safety measures.
In addition, documented impact tests can contribute to improved evaluation of residual risks within a machine design.
By understanding the load-bearing capacity of a guarding system, engineers and safety specialists can better determine whether additional measures are required.
In modern production environments, where safety, availability, and reliability are becoming increasingly important, the demand therefore continues to grow for machine guarding systems with objectively tested and documented performance.
Machine guarding forms an essential part of industrial machine safety and plays an important role in reducing risks within automated production environments. However, the effectiveness of guarding is not determined solely by the design or the presence of safety components, but primarily by the extent to which the system can withstand realistic mechanical loads.
Impact testing therefore forms a crucial part of the validation of machine guarding systems. By testing systems in accordance with EN ISO 14120:2015 and using TÜV-certified test methodologies, it can be determined whether guarding systems maintain their safety function under dynamic loading conditions.
Troax applies these test methodologies to panels, doors, fastening systems, and supporting structures in order to assess the structural integrity of the systems. In doing so, the solutions support machine builders and end users in creating safe production environments that comply with international safety standards.
In an industrial environment where automation and dynamic loading continue to increase, reliable and demonstrably tested machine guarding remains a fundamental component of effective machine safety and risk reduction.
We offer a range of standard Troax panels, doors, and posts in our webshop. You can find these here. Are you looking for a custom-made solution? Please contact us by sending an email to sales@usp-safety.com or by calling +31 (0)10 – 822 44 00.
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