DIOSH Day Peoria, Illinois March 1, :50-2:40pm

Transcription

1 DIOSH Day Peoria, Illinois March 1, :50-2:40pm OSHA General requirements (a) (1) protect operator & other employees in the machine area from hazards Machine Safeguarding Overview Roger Harrison - Director of Training (815) roger.harrison@ point of operation ingoing nip points rotating parts flying chips & sparks 1 examples of safeguarding methods: barrier guards, two-hand actuators, electronic safety devices, etc. 2 Code of Federal Regulations OSHA Sub-Part O Machinery and Machine Safeguarding Definitions General requirements for all machines Woodworking machinery (ANSI 01.1) Cooperage machinery (barrel making) Abrasive wheel machinery ANSI B11.9 ANSI B Mills and calendars (rubber and plastics) Mechanical Power Presses (ANSI B11.1) Forging machines (presses and hammers) Vertical = specific Mechanical power transmission apparatus 3 Horizontal = general 5 Safeguarding Methods in ANSI B11.19 Guards: Prevent access to Point of Operation Devices: Control access to Point of Operation Distance: Large piecepart size/shape prevents (Safe Holding) Operator from reaching the P.O.O. Location: (Safe Position of Controls) Operator not required to be in the in Point of Operation hazard area Safe Opening: ¼ or less opening at P.O.O. 4 Severity of Injury Minor Serious Major 10 Fatal Probability of Injury Unlikely Possible Probable 6 Certain Level of (Hazard) Exposure Determines Safeguarding Frequency of Exposure Seldom Occasional Frequent Medium +Avoidance Severity + Probability + Frequency = Level of Exposure to Hazards High Low Add any additional factors to this total Seldom Probable Major ANSI B11.TR Risk Assessment/Risk Reduction 5 Higher Levels of Exposure require More Effective Safeguarding ANSI B11.TR

2 ANSI B Safeguarding of Machinery and Risk Assessment 6.1 General... Suppliers and users are required to perform risk assessment 4.2 Collaborative efforts... the supplier shall advise the user of residual risk Safeguarding...The supplier shall provide safeguarding determined by risk assessment. 4.6 Safeguarding... The user shall ensure that additional safeguarding is provided and installed as determined by risk assessment. 7 Tail-out Barrier Awareness Barriers for lower level EXPOSURES 8 5 concerns on any machine Safeguarding - guard, device, method Controls - control reliability Disconnect and other LOTO devices Starter - magnetic (drop-out protection) Covers - rotating components covered to (7 feet - OSHA) from floor/working platform (8 feet - ANSI) (10 feet European Stds.)9 Rotating Motion Nip Point Rotating Motion Nip Point Nip Point Nip Point Nip Nip Point Point Rotating Motion 7-foot covers meet OSHA 8-foot covers meet ANSI Nip Point Rotating/Reciprocating Motion 10 EN Safety Related Parts of Control Systems Category B Category 1 Category 2 (mats, drop probe, R/F) Category 3 (some guard interlocks) Category 4 safety-related parts of machine and safeguards components withstand environment well tried safety components and principles components monitored before machine start-up and periodically dual/monitored system of critical components single fault does not lead to loss of safety function dual/monitored system with all (some light curtains) foreseeable faults detected 11 DETECTION of faults PREVENTION of faults European Safety Regulations: Current: EN 954 New: EN/ISO and EN/IEC don t confuse with 5 Safety Device Categories currently in use (e.g. category 4 ) don t confuse with 3 Categories of Stop Controls already in NFPA (categories 0, 1, 2) contains 3 Safety Integrity Levels (SIL-1, SIL-2, SIL-3) based on: Severity, Frequency, Probability, Avoidance and formulas: MTTFd mean time till dangerous failure contains 5 Performance Levels (PLa, PLb, PLc, PLd, PLe) 12 2

3 Control Reliability for Solid-State Controls ANSI B Annex E DUAL Microprocessors with Independent Power Supplies are preferred Most name-brand DEDICATED MICROPROCESSORS comply with this AVOID SINGLE PLCs for Press Controls 13 Presence Sensing Safeguarding Devices Safety s / Screens Single and Multiple Safety Beams Safety Mat Systems Area Scanning Systems PSSD s Area Laser Scanners Radio Frequency (capacitance) Drop Probe (Ring Drop) devices 14 Presence Sensing Devices can only be used on machines that can stop consistently and immediately anywhere in their stroke or cycle without damaging: machine - tooling work or creating another hazard Point of Operation 15Perimeter (Area) -Single or Continuous 16 Two-hand Control for Cycle Actuation / Safeguarding 17 Larger dead-zone is at TOP instead of the BOTTOM of this Muting (c)(3)(iii)(d) TDC Bypasses output 360 signal of P.S.D. P.S.D. Active on upstroke on downstroke Muting used for: 1) parts ejection 2) circuit checking 3) material feeding Muting done in timing circuit of press control Crankshaft 270 Rotation P.S.D. Muted on upstroke /4 die opening 18 3

4 Light Curtain Blanking MOS Identified... Don t Blank too many 20 Don t Mute too early Front-surface mirrors reduce range about 12% 3-sided includes the coil feed 21 Stainless-steel mirrors about 18% - shatterproof 2-sided Perimeter 22 Safety Distance: and 2HC 2-hand Controls rules to be a SAFEGUARDING DEVICE: Protect from unintended operation, Anti-Repeat, Concurrent ½ sec max, Holding-time, Interrupted-stroke Anchored at Safety Distance, etc. 23 No-Force Actuators mounted on swivels for ERGO when Operators are using a 2 HC for high-repetition 24 4

5 OSHA Safety Distance Formula 2-Hand Control or Stopping Time in seconds at 90 crankshaft position x 63 inches per second (hand speed constant) = minimum safety distance in inches.200 x 63 = 12.6 Safety Distance TDC Crankshaft Rotation STM FLAG NOT interrupting STM FLAG interrupting 26 Light Curtains FLYING OBJECTS NO PROTECTION Noise Impact Coolant 27 Guard / Combination 28 Vertical - Small MOS Blankers increase Safety Distance Don t leave the KEYS in s or in Press Mode Selectors Horizontal - Large MOS MOS = Minimum Object Sensitivity differs for each make/model of 29 Red: obstructed Amber: blanking Green: clear 30 5

6 Function Testing s before every operating shift Function Test Checklist steps on this plasticlaminated quickreference guide are generic. Refer to specific procedures from the manufacturer of your light curtain 31 Function Testing Procedure ANSI B Guards and devices must be checked... s should be only be installed, checked out, and maintained by a Qualified Person a person or persons who, by possession of a recognized degree or certificate of professional training, or who, by extensive knowledge, training and experience, has successfully demonstrated the ability to solve problems relating to the subject matter and work. ASME B ANSI B lots of new information on Safety Blocks Interlocked Safety Block 33 The Minster Machine Company (419) Manual #805E Minster, OH National Safety Council (800) # Roselle, IL ANSI B Press Brake Safeguarding Blanking required No Blanking required Feed line height Feed line height - Press Brake bending operation 35 Can reach over or under LC adjustable height table Can t reach over or under LC 36 6

7 LazerSafe Safeguarding System ONLY FOR HYDRAULIC PRESS BRAKES AOPD - Active Opto-Electronic Protection Device Close-proximity Point-of-Operation Laser AOPD Device mounted with ZERO Safety Distance ANSI B Laser Safeguarding Devices for Hydraulic Press-Brakes AKAS III - Fiessler Electronik - (Bystronic PB s) BendGuard - (Trumpf Tru-Bend PB s) Laser Sentry - Metal Tech Controls V SICK Automation Lazer Safe - Scientific Technology Inc. Laser Beam - Zakron DSF ANSI B Close Proximity Point-of-Operation AOPD Active Optical Protective Devices 38 Laser Device hand-holding small parts Down-acting Hydraulic Press Brake 39 Laser Device for parts with tall side-legs Up-Acting Hydraulic Press Brake 40 Close Proximity Point-of-Operation Active-Optical Protective Device (AOPD) Robotically-fed Press Brake with Perimeter LazerSafe for Hydraulic PB s is mounted at ZERO Safety Distance 41 Interlocked Perimeter Guard 42 7

8 Safe Speed Safeguarding ANSI B This method of safeguarding only applies to bending operations on press brake production systems... acceptable when the following conditions are met: a) Safe speed is a ram speed of 10mm/sec (0.39 inches/second) or less... using a three-position hold-to-run control b) If a press brake is capable of exceeding this speed, one of the following methods of monitoring is required... i) if the control of safe speed is through non-variable means, then continuous monitoring of the control devices is required ii) if the control of safe speed is through the use of variable parameters, then continuous monitoring of the speed of the ram is required. A stop shall occur if the safe speed is exceeded. 43 and Manual Gate protect Operator Lexan Guarding keeps other people out of POO and Two-hand 44 Control protect Operator Point of Operation Guard Requirements OSHA (c)(2) and ANSI B (8)(5) O.U.T.A. can t reach through, over, under, around meets Table 0-10 for openings and distances no pinch points between guard & moving parts good visibility into the point of operation fasteners not readily removable (tool required) *materials strong enough to protect people *free from sharp edges that could injure people 45 Over, Under, Around, Through? 46 OSHA Guard Opening Scale 1948 Liberty Mutual and ANSI Standard writing committee Guard Opening Scale Comparison OSHA ANSI ANSI Guard Opening Scale 1996 Liberty Mutual and ANSI Standard writing committee OSHA ANSI

9 Newer Guard Interlock Switches KEY geometry makes it difficult to defeat KEY forces a make/break of electrical contacts Risk Assessment for Interlock Reliability KEY KEY Latching Minor Risk Cat. 1 Serious Risk Cat. 2 Major Risk Cat Fatal Risk Cat Function Testing Point of operation Guard 2 Reasons to Function-test Guard Interlocks before starting each new operating shift: 1) to make sure the interlock WORKS 2) to make sure it has NOT been CHEATED 51 OTHER FTC s: s, 2-Hand Controls, Perimeter Guards, etc. ANSI B Abrasive Wheels ANSI B Grinding Machines 1/4 maximum opening Both ANSI Standards Covered spindle end/nut OSHA (a)(2)(i) Direction Arrow Both ANSI Standards 1/8 maximum opening for Work Rest #1 OSHA Machine Safeguarding violation-every state in the U.S.A. OSHA (a)(4) 52 Blade-guard extension was added per OSHA Area Guarding: 2 Safety and 2 Warning Zones, horizontal mounting Access Guarding: 2 Safety Zones, vertical mounting, using contour-as-reference 53 SICK Incorporated Area Guarding: 1 Safety and 1 Warning Zone, horizontal mounting 1 2 Area Laser Scanners Access Guarding: 1 Safety Zone, vertical mounting, 54 using contour-as-reference 9

10 Area Laser Scanners on AGV s 55 reprinted with permission SICK Inc. Area Laser Scanner Laser Class 1 IEC 1496 Type 3 IEC SIL 2 56 Area Laser Scanners 57 Two-hand Control on floor pedestal YES 58 L-shaped Mats on a Tube Bender NO 3-sided Perimeter Laser Scanner Awareness Barrier Floor Markings Mats must be fastened to floor to prevent moving them too close to the hazard area 59 Laser-cutting System 60 10

11 Material Handling for Laser-cutting system Bump Switch Radio Frequency and Lexan Guards Laser Scanner Grab-wire E-stop cables Drop-Probe Devices Ring-drop Devices Halo Devices ANSI B Also see ANSI B Rivet Setting Equipment Mechanically verifies the absence of hand or fingers in Point of Operation Riveters, Spot Welders, Staplers, Stakers Eyeletters, Terminators, Dinkers, Clickers 63 Riveter with a Drop-Probe Drop-Probe Device on a Spot-Welder 64 reprinted with permission Scientific Technologies Inc. Rotary Interlock Point of Operation Magnetic interlock Pressure sensitive mat Actuator operated interlock Solenoid locking interlock Actuator operated interlock Grab-wire E-stop cable Point of Operation knows difference between car and person 65 Combination of Safeguarding Devices 66 reprinted with permission SICK Inc. 11

12 Perimeter Guard on Robot Cell Polycarbonate Vision Panels 67 ANSI B Annex E Considerations for Transparent Guards When R/A shows that A/B are not enough: R/A Risk Assessment A/B Awareness Barrier 68 Perimeter Guarding for Auxiliary Equipment 12 inch sweep and 60 inch height (ANSI/RIA) R inch (.15m) sweep, 72 inch (1.8m) height (CSA) 2003 Perimeter Guard on a Robot Cell Danger and Warning Signs Pictograms

13 Rope Pull Cable type of E-Stop requires reset when tripped Latching Pull-switch 73 Cable runs longer than 20 may need a switch on BOTH ends These and others are free downloads; cemanet.org Conveyor Equipment Manufacturers Association 74 Belt Conveyor This meets NFPA 79 Electrical Standard for Industrial Machinery Reset Reset ANSI B (1) Conveyors that start up automatically require an Audible or Visual Warning Device that can be clearly seen or heard at all points that people may be present Red E-Stop Cables ANSI B Manual reset or start at the location where the Emergency Stop was initiated required to resume operation 75 Red Button Yellow Background Manual Latch Engaged Disengaged76 Article Electrical Safety Program (A) General. The employer shall implement and document an overall electrical safety program that directs activity appropriate for the voltage, energy level, and circuit conditions. Source: Littlefuse NFPA 79 Electrical Standard for Industrial Machinery 2015 Edition Main Power Disconnects - Motor Starters Voltages - Grounds - E-stops - and more Category 1 Stop Controls Category 2 Stop Controls Category 3 Stop Controls 78 13

14 #1 Hazard - starting lathe with key in chuck Spring Loaded Chuck-Wrench Hinged Chuck Shields all in the open position to prevent wrench from being left in chuck www. Chip/Coolant Shield with built-in Interlock Hinged Chuck Shield with built-in Interlock 81 Telescopic stainless-steel sleeves cover horizontal rotating components 82 Down position Releasing and Lifting Telescopic Chuck Shield ANSI B Movable Guards shall provide access to hazard areas without the use of tools Universal Ball & Socket Shields One section locked up Up position