Presented by: Wadesboro, NC 28170

Transcription

1 Flexible Packaging Association Environmental Summit / Safety Conference Welcome to Hoists and Manipulators Operational Safety and Compliance Presented by: COFFING HOISTS 2020 Country Club Rd * PO Box 779 Wadesboro, NC

2 Agenda About COFFING HOISTS OSHA Code of Federal Regulations Inspection classifications Manipulator Terminology Types of Manipulators Standard Crane Signals Sling Inspection Procedures Questions & Answers

3 COFFING HOISTS Originally established in Danville, Illinois. Acquired by Duff-Norton Company of Charlotte, NC in Moved to present location in Wadesboro, NC in Since under going three plant expansions, the 180,000 sq. ft. Wadesboro facility currently employs 175 associates. The employees pride themselves in offering a wide range of products to meet lifting, puling and rigging needs. Years of engineering know-how, dedication to superior manufacturing and valued customer input have led to the design and continuous refinement of each Coffing product.

4 OSHA vs. ASME OSHA Occupational Safety & Health Administration Regulations are Law Manufacturers required to comply Users required to comply Should & Shall? ASME American Society of Mechanical Engineers Created by nation s leading authorities on hoists and cranes. It may be as legally binding as OSHA and must be cited referencing the general duty clause of Must be serious violation to be cited.

5 ?? WHAT ARE WE TALKING ABOUT?? CFR CFR ANSI B30.2 GIRDER ANSI B30.9 ANSI B30.10 ANSI B30.11 ANSI B30.16 ANSI B30.17 ANSI B30.20 ANSI B30.21 OVERHEAD AND GANTRY CRANES SLINGS OVERHEAD AND GANTRY CRANES (TOP RUNNING) SINGLE/MULTI SLINGS HOOKS MONORAILS AND UNDERHUNG CRANES OVERHEAD HOIST (UNDERHUNG) OVERHEAD AND GANTRY CRANES (TOP RUNNING) SINGLE GIRDER UNDER BELOW THE HOOK LIFTING DEVICES MANUALLY LEVER OPERATED HOIST

6 Inspection Classification Initial Inspection Prior to initial use, all new, altered, or modified cranes shall be inspected by a designated person to ensure compliance with applicable provisions. Frequent Inspection Visual examinations by the operator or other designated personnel with records not required. Normal Service monthly Heavy Service weekly to monthly Severe service daily to weekly Source ASME B30.17

7 Inspection Classification Periodic Inspection Visual inspection by a designated person making records of apparent external conditions to provide the basis for a continuing evaluation. Normal service yearly Heavy service semiannually Severe service quarterly Source ASME B30.17

8 Required Inspections Cranes & Hoists Daily visual and Operational Inspection by the operator every shift. Frequent inspections of braking systems, upper limits, hook, chain, and wire rope. Periodic Inspections (minimum once per year) signed by a qualified person. Slings Each time they are used by the operator. Annually with signed reports by a qualified person. Below-the-Hook Devices Daily by the operator. Annually with signed reports by a qualified person.

9 MANIPULATOR: Device used under human control to manipulate materials without human contact. Manipulators can move objects vertically or horizontally. Perform functions such as rollover, tilting, pouring, and dumping. Often combined with a lifting device for handling materials. Lifting devices include air lifts, electric hoists, balancing hoists and cylinders. Steps involved in installing an industrial manipulator. 1. Define the required task. 2. Establish the acceptable range of operation parameters. 3. Design the system for integrating workers, machines, and materials. 4. Prepare required documentation for the project. 5. Monitor the installed manipulator. Manipulators can have a direct effect on improving a company s profits 1. Increased Productivity - through utilizing machine tools for long cycle times. 2. Operator Fatigue increased strength and reach capability. 3. Dependable Product Handling ease, speed, and reduced damage in handling heavy and awkward loads, machine tools, fixtures, and cutting tools 4. Maintenance of Quality Standards increases the efficiency of operation and improves worker safety

10 Manipulator Types Jib Air balancers Low-Profile Articulating Jib

11 Jib Crane Jib crane is the simplest manipulator Rotating boom Mounted vertical position by floor, ceiling, or wall Generally pneumatic or electric Heavy assembly Loading machine tools Forging presses Requires operator to pull and push the load

12 Greater versatility Articulating Jib Secondary 360 degree pivoting arm Reach where standard cranes cannot Working area of up to 40ft in diameter Ceiling, floor, or overhead mounted Ideal for pneumatic hoist Practical with overhead space limitations

13 Balancer Provide free triaxial movement Vertical, horizontal, and rotational Near weightless conditions Utilize your natural movements Supported and controlled at all times Little or no restrictions

14 Balancer Balancer limitations: Headroom requirements (approx. 12ft) Lift Reach and Capacity Reach-in (parallel linkage arms) Cycle Time Side Loading

15 Low-Profile Used where overhead obstructions ti or low ceilings exist Provides triaxial movement Operator manually activates horizontal sluing Hydraulic rotary actuators Headroom requirements are reduced

16 Low-Profile Low-Profile limitations: Reach Capacity Speed (hydraulics slower) Space requirements (floor space for hydraulic reservoir/pumps) Side Loading Operation Position (operator positioning) Work Envelope (true vertical/horizontal movement) Lift (must be evaluated)

17 Hoists Types: Wire rope Link chain Roller chain Powered by: Electric Air

18 Balancing Hoists Perform Three (3) basic functions 1. Balance tool and fixture suspension 2. Handle varying weight loads (Pistol-grip metering valve) 3. Constant weight-handling handling applications (custom grab)

19 Balancing Hoists Limitations: Loads over 500 lbs do not have full float capabilities with pistol-grip i models Heavier loads do not have as much overhead bridge ease of movement Side loading makes movement much more difficult and causes excess wear Generally must keep the load well centered under bridge crane and in relation to work station Strict attention to: a. Securely gripping load b. Having unit in proper up/down mode c. Having load in place when starting up cycle

20 Manipulator Mounting Most manipulators are designed d to be mounted: 1. Floor concrete foundation pad/anchor bolts 2. Dolly mounted allows unit to be moved (must be leveled at each setup) 3. Ceiling suspension clear floor area (adequate to handle manipulator and its rated load) 4. Trolley mounted function in more areas Manipulators are seldom mounted to the wall. Most common method is on the floor.

21 Advantages & Disadvantages Pneumatic: Power Sources Minimum line pressure 90 psi Do not have self-destructive characteristics that are subject to heat & resistance Do not require cooling Control components are much smaller Precise positioning through compressibility of the pneumatic media Explosion proof Hydraulic: Cooled by passing fluid through heat exchangers Higher density than dry air Shock load concern during acceleration and deceleration Require floor space for locating reservoirs Actuators offer the highest torque Messiness through leaks Require initial time to allow hydraulic fluid to warm up to operating temperature Additional electrical l power supply to run the pump Noisy operation

22 Safety checklist: Safety Considerations Movements, Posture and Layout Assessment Is the task repetitive? Is there frequent or prolonged bending down where the hands pass mid thigh? Is there frequent or prolonged reaching above the shoulder? Is there frequent of prolonged bending due to extended reach forward? Is there frequent or prolonged twisting of the back? Are awkward postures assumed frequently or over prolonged periods, that is postures that are not forward and upright?

23 Safety Considerations Task and Object Assessment Is manual handling performed for long periods of time Are loads moved or carried over a distance? Is the load weight more than 35 lbs (non-seated)? Is pushing or pulling required? Is the difficult or awkward to handle i.e size, shape, temperature, instability, and unpredictability? Is it difficult to get an adequate grip of the load? Does it require two or more people to lift?

24 Design guidelines: Grab and Manipulator Structural parts should have 3:1 safety factor on yield, 5:1 on ultimate strength Clamping force must be maintained even if activating force is lost Friction force must be two times the maximum load Sufficient vacuum to hold a minimum three times the maximum load Magnet must lift three times the maximum load Electromagnets must have backup power source / switch for power failure Battery failure warning device when lifting falls below the 3:1 safety facture Identified with maximum rated load capacity General guidelines for strength of operator: a. Finger press: 5 lb b. Finger pull: 5 lb c. Forearm lift: 25 lb d. Two-hand scissor action/elbow height/hands 8in apart/standing: 18 lb e. One-hand lever type control standing; push: 75 lb pull: 70 lb f. Hand crank/elbow height ht with 4-10 in crank: 30 in lb NOTE: (For Males, these figures could be increased by 40%)

25 Safety Considerations 1. Interruption of the power supply due to failure or pinching of the hoses. Loss of power would result in manipulator arms dropping rapidly. 2. Loss of load due to the grab losing grip on the product. If powered by a pneumatic cylinder, loss of the load will result in rapid expansion of air in the lifting cylinder. The manipulator arms would then rise at a high velocity. 3. Accidental release of the grab by the operator. Hazard control devices: 1. Up-Speed control Limits the upward velocity, provides protection in the event the load is lost. 2. Down-Speed Safety Control Restricting the velocity of air exhausting from the lift cylinder when the arms are being lowered. 3. Interlock Integrate the control of the pneumatic clamping grab and main lifting circuitry. Interlock will not allow the operator to release the grab from the product until the load has been set down. 4. Grab-Lost-Load Load Control Safety device incorporated prevents a load from being released from the grab due to loss of air pressure. 5. TRAINING: Competent operator, who is trained to use industrial manipulators. Training should cover how the manipulator is to be used, all the safety features that have been built into the manipulator, and the limitations of the manipulator.

26 Mechanical Mechanical requires no power source, grabs activated either by the operator through a mechanical linkage, self-activated by the weight of the material being handled, or grab is designed to cradle the material.

27 Vacuum Grab Flat or gradual contour surfaces. Can pick up glass sheets, sheet metal, rubber sheets, office furniture, and cardboard cartons.

28 Powered External & Internal Clamp External - Hydraulic or Pneumatic powered means for activation of the clamps. Internal - Flexibility and frees the outside surface of the object being handled.

29 Standard Crane Signals

30 Standard Crane Signals Hoist With forearm vertical, forefinger pointing up, move hand in small horizontal circle. Lower With arm extended downward, forefinger pointing down, move hand in small horizontal circles.

31 Standard Crane Signals Bridge Travel Trolley Travel Arm extended d forward, hand Palm up, fingers closed, open and slightly raised, make thumb pointing in direction of pushing motion in direction of motion, jerk hand horizontally. travel.

32 Standard Crane Signals Stop Arm extended, palm down, move arm back and forth. Emergency Stop Arms extended, palm down, move arms rapidly back and forth.

33 Standard Crane Signals Multiple Trolleys Move Slowly Hold up one finger for block Use one hand to give any marked 1 and two fingers for motion signal and place other block marked 2. Then use hand motionless in front of regular signals. hand giving g signal. (Hoist slowly shown as example)

34 Standard Crane Signals Magnet Power On Left arm extended overhead, hand clenched, fingers front, hold position rigidly. Magnet Power Off Left arm extended overhead, hand open, palm front, hold position rigidly.

35 Standard Crane Signals Magnet is Disconnected Crane operator spreads both hands apart palms up.

36 SLINGS ref. CFR CFR ASME B30.9

37 INSPECTIONS Initial: Prior to use, all new, altered, modified, or repaired slings shall be inspected by a designated person. Frequent: A visual inspection for damage shall be performed by the user or other designated person each day or shift the sling is used. Written records are not required for frequent inspections. Periodic: A complete inspection for damage of the sling shall be periodically performed by a designated person. Periodic inspection intervals shall not exceed 1 year. A written record of the most recent periodic inspection shall be maintained and shall include the condition of the sling. ref. ASME B30.9

38 Where to Get More Information Visit our website: com Visit OSHA website:

39 Special Thanks To YOU