Safety standards for machinery

There are two basic questions that Morello’s technical project office always asks when designing a new machine:

Does the machine do exactly what the customer needs?
Is the machine safe?

Along with machine performance, Morello uses the safety factor as a fundamental design principle when studying and designing a new machine.

When moving materials of different weights and sizes, it is an absolute priority to take all necessary precautions to ensure that the heavy truck or its load does not cause injury or damage to persons or property.

For this reason, for each machine designed by Morello and in accordance with the regulations of the European Machinery Directive 2006/42/EC, a detailed risk analysis is carried out to identify all the possible risks that the machine may encounter or risks that arise when the machine can be used.

In order to guarantee appropriate safety standards, all Morello machines, regardless of the final country of destination, are CE certified, of course meeting local guidelines and regulations. During the machine design process, Morello, in addition to following the European Machinery Directive, also follows all product-specific regulations, thus guaranteeing the highest safety standards.

Structural safety

At the structural level, the machine’s supporting structure is calculated using a high safety factor that exceeds the limits and requirements prescribed by the regulations.

For structural calculations, Morello uses advanced FEM analysis software as well as traditional spreadsheet calculations that allow for a more detailed analytical view.

The design of all structural welds is supervised by an experienced welding coordinator

In order to guarantee the safety of the machine design after the design phase, it is essential that Morello manages the production phase with the utmost care and attention. Particular importance is attached to the materials used, the welds themselves and the welding process. A 3.1 certificate is required for all construction materials and procedures are in place to ensure the continued traceability of these materials.

Every single weld is inspected by a qualified Morello inspector. The non-destructive tests used are: visual method, penetrating fluids, magnetoscopic and, at the customer’s request, ultrasonic or radiographic.

To ensure strict adherence to the above processes and in compliance with international standards, Morello has obtained ISO 3834-2 certification issued by DNV.

Electrical and electronic safety

Morello designs the electrical and electronic systems (as well as all other parts of the machine) according to the results of the risk analysis and in compliance with the relevant product regulations. The performance level or SIL is then defined according to the requirements (or customer requirements) and the entire system is designed accordingly.

For both automatic machines and operator-controlled machines, Morello uses all the necessary safety components needed to minimize, if not eliminate, the risk to the machine operator.

Where appropriate, safety laser scanners, safety PLCs, multiple safety sensors, safety communication networks (both wired and Wi-Fi) and other components are used. All in accordance with the strictest national and international safety standards.

Inspections, testing and trials

To meet the above requirements and standards, Morello has clearly defined internal procedures to ensure that all activities are carried out efficiently during the various phases of design and production. At the end of all key phases of the project, checks and tests will be carried out to verify that each task has been carried out correctly.

Finally, when the machine is completed, a rigorous acceptance test is performed to verify that every single aspect of the machine has been manufactured in accordance with the original project design and as defined therein.